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OPERATIONS MANUAL
ELECTRIC WINCHES 230/400 VOLT
[CP.0.DPS / DPT series]
CP.0.DPS SERIES 230 VOLT
CP.0.DPT SERIES 400 VOLT
NOTE: All of the information reported herein is based on data available at the moment of
printing. We reserve the right to modify our own products at any moment without
notice. Please read the operating instructions carefully before using this product.
Always keep a copy of this instruction manual at hand. Failure to read and comply
with the contents of this manual can result in serious body injury or death, and
property damage.
THIS IS THE SAFETY ALERT SYMBOL. WHEN YOU SEE THIS SYMBOL
ON YOUR PRODUCTS OR IN THIS MANUAL, BE ALERT FOR
DANGEROUS SITUATIONS. FOLLOW RECOMMENDED AND SAFE
OPERATING INSTRUCTIONS AT ALL TIMES.
If any doubt remains, please contact your supplier.
2
PRECAUTION – SAFETY WARNINGS
The user of the electric pulling winch must always check if guidelines are followed,
which you can find in this manual. Also he/she needs to understand the manual and user
instructions completely for safety purposes. Please note that if not followed or understood
correctly, potential risks are even greater and can lead to severe injuries or equipment
damage. Therefore it is always recommended to save this manual correctly, accessible for
the any person who is going to use it.
Never use or install electric pulling winch before understanding the user manual
completely.
electric pulling winch may only be used by qualified personnel of age. Make sure
that people who are using this for the first time are familiar with the correct operation
instructions and have knowledge about the safety requirements. The user must have a
good mental and physical condition.
Never remove the nameplate, operating and warning labels. Do not use this product
without.
Do not exceed the rated capacity, which you can find on the nameplate. If not, do not use.
Always make sure that the supporting structures and additional pulling equipment are
rated equally or higher to support the rated capacity of electric winch.
Before installing, make sure that electric pulling winch, wire rope, and other
components are visibly in good condition. After installing periodically inspect these, to
make sure that this is kept. If not, please contact your supplier or another professional.
The ambient temperature of electric winch and load must be between -10 °C / + 40
degrees °C
A technical study by a professional must be carried out before instalment to prevent any
risks.
Make sure that the electric pulling winch is correctly mounted with the pre-designed
holes. Make sure that bolt and nuts are tightly secured.
Never use the electric pulling winch for pulling, lifting, supporting or transporting
people.
Never lift loads over or in close proximity of people.
Always inform the surroundings that the pulling / lifting procedure is going to start. Make
sure that no obstacles are in between the winch and the load.
People may never walk under the suspended load or stand in close proximity. (Danger
zone) Never let people stand near the load. Make it clear. Never leave load unattended.
Maintenance and repairs must be done by professionals and qualified companies. Always
use spare parts. Always make sure to keep a journal.
Never operate a damaged or malfunctioning electric pulling winch. Always re-test
the electric winch after reparation.
If you have any questions ,please contact your supplier.
3
CONTENTS
Introduction Page 4
1. Mark definition Page 4
2. Safety instructions Page 4
2.1 General rules Page 4
2.2 Check before operation Page 5
2.3 Warnings during operation Page 5
2.4 Finished operation Page 6
2.5 Inspection and maintenance Page 6
3. Technical data Page 6
3.1 Operation condition and environment Page 6
3.2 Technical parameters Page 7
3.2.1 electric winch specifications Page 7
3.2.2 electric winch capacity per layer Page 8
3.2.2 electric winch dimensions Page 9
3.3 Main characteristics Page 10
3.4 Machine classification and period of use Page 10
3.4.1 ISO/JIS Classification Page 10
3.4.2 Fem Classification Page 10
4. Safe operation Page 11
4.1 Declaration Page 11
4.2 Install and test Page 11
4.3 Test before operation Page 11
4.4 Inspection Page 11
5. Installation Page 12
5.1 Pre installation check Page 12
5.2 Mounting holes of electric winch Page 13
5.3 Initial lubrication Page 13
5.4 Connection to electrical supply Page 13
5.5 Starting Page 13
6. Operation Page 14
6.1 Selection and qualification of operating personnel Page 14
6.2 Operating safety instructions Page 14
7. Maintenance Page 16
7.1 Checking references Page 16
7.2 General rules Page 16
7.3 Wire rope replacement Page 17
7.4 Oil lubrication Page 17
7.5 Malfunctions and solutions Page 18
8. Spare parts & Diagram Page 20
9. Derived certificate of test & Declaration of CE conformity. Page 40
4
INTRODUCTION
electric pulling winches are designed for pulling and lifting load in a safe working
environment. The user is responsible for correct operation and must always make sure that the load
weight doesn't exceed the rated capacity. If used for lifting purposes, please contact a professional
and carry out a risk analysis. Also any modifications made on the electric pulling winch is the sole
responsibility of the user / owner. will not be responsible for any problems caused by
modifications, wrong use, or any other abnormal situation.
electric winches are in compliance with the safety factor and further safety requirements in
conformity with the European Communities Machinery Directives 2006/42/EC.
Illustrations are for the general understanding and may differ from the actual versions
reserve the right to change materials or design, if, in our opinion, such changes will improve
our product. For the correct use of the electric winch, operation and maintenance instructions
must be followed. Abuse, repair by an unauthorized person, or use of non- replacement parts
voids the guarantee and could lead to dangerous operation.
Please read the instructions carefully before using this product.
1. Mark definition
electric winch are designed for pulling load, which has to be used under normal working
conditions. It is strictly forbidden to pull or lift persons. The manual use the below markings to
identify the level and grade of danger.
DANGER Very dangerous situation, if the danger is not avoided, it will cause
death or serious injury.
WARNING Potential dangerous situations, means if the warning is not heeded, it
can cause death or serious injury.
CAUTION Pre-caution needed, if the precaution is not taken, it may cause minor or
moderate injury.
According to these instructions, caution markings can also lead to serious injuries. Therefore is
important to follow the safety instructions in this manual, but also use common sense when using
electric winches.
2. Safety instructions
2.1 General rules
Wrong use or lack of maintenance can lead to dangerous situations, which has to be taken seriously
during and after use. For example, a dangerous situation as where the load cannot be pulled or lowered
to a stable and flat underground.
Before installation, operation or maintenance , please read the content of the manual and obey all
safety, operation, maintenance instructions.
We will not be responsible for any problems caused by modifications, wrong use, or any other
abnormal situation. If the products was not use in nonstandard application, please advise with the
local distributor in advance. Also you need to make a risk analysis by a professional to avoid very
dangerous situations.
5
2.2 Check before operation
CAUTION
This manual is formulated for winch operators. Before the operator start to work,
he should know all the contents of safety and operation instructions. If the
products has deformation or cracks problem on the hook, wire rope, winch please
do not use, You should contact your dealer and change parts, please do not use
any non-spare parts.
WARNING It is strictly forbidden to repair the wire rope which is installed on the
electric pulling winch. Always replace accordingly.
CAUTION The electric winch may only be used, when the installation (earth) are correct.
CAUTION When the steel wire has severe wear or damage; do not use the winch. Replace.
CAUTION Pre-operational procedure; please make sure to carry out the pre-check
instructions as mentioned in the manual.
CAUTION Asses the weight of the load; select the winch, which is suitable for your
application and use the correct rated capacity.
CAUTION
Check if the winch is firmly mounted to a stable and flat underground by using
the pre-designed fixing holes. Make sure that bolt and nuts are tightly secured.
The bottom hook must be complete and in good condition, so assure that it has no
deformation or loose components. Safety lock mechanism must be in place.
CAUTION Check the winch for correct functioning, the brake needs to hold the pulled
load.
CAUTION When the temperate is below 0°C, check the brake at all times.
2.3 Warnings during operation
WARNING It is strictly forbidden to use the winch with damaged or worn out wire rope.
CAUTION Do not use the steel wire as heavy duty sling.
WARNING Do not pull goods in an angle. No side pull.
CAUTION Do not place the load on the tip of hook.
WARINING Make sure that the wire rope does not pass through / against obstacles such
as steel plates.
WARNING It is not allowed to perform any welding / cutting operations when the load
is pulled.
WARNING Don’t swing suspended goods.
WARNING Don’t use winch, which has an abnormal / broken sound.
WARNING Don’t quickly repeat pull and release buttons.
WARNING Forbidden to leave pulled goods unattended.
WARNING Please place hook in the centre of the gravity of the load
CAUTION electric winch are designed for pulling winch, of used as lifting,
please contact a professional. Before lifting, calculate the weight.
6
2.4 Finished operation
WARNING After operation, please make sure the weight is completely resting on a flat
service to avoid the load from dropping.
WARNING When the operation finished, cut off the control pendant in order to avoid
wrong operations by others.
DANGER
Emergency procedure: In the event of a blocked steel wire or any other
malfunction of electric pulling winch, immediately stop the
maneuverer without attempting any further actions. Immediately set up a
safety perimeter around the winch and the load to prevent access by any
unauthorized persons. Call in the necessary personnel to remove the load
and intervene on the winch. 2.5 Inspection and maintenance
CAUTION Professionals must inspect and maintain the winch regularly
otherwise, please contact your dealer to inspect and service the winch.
WARNING The wire rope cannot be repaired, it must be replaced when damage or
wear is severe.
WARNING
It is forbidden to use the winch, which has any problems or
obvious signs of damage. Also during maintenance it may not be used.
Also do not use wire rope which is damaged.
3. Technical data
3.1 Operation condition and environment
Temperature operating range: -10°C ~ +40°C
Relative humidity: <85%, this product is not designed for underwater use.
electric winch is not suitable to use in fire, explosion risk or corrosive gas environments , also
It cannot be used for lifting melted steel, poisonous, inflammable and explosive goods
7
3.2 Technical parameters
3.2.1 electric pulling winch specifications
Model DPS-200 DPS-250 DPS-300 DPS-500
Capacity (kg) 200 250 300 500
Pulling range (m) 28 28 28 43
Standard Control cable (m) 2 2 2 2
Operation voltage / single phase 230V 230V 230V 230V
Cycle (hz) 50 Hz 50 Hz 50 Hz 50 Hz
Power output (watt) 370 600 750 1500
Pulling speed (m/min) 14.1 14.1 14.1 18.9
Wire rope diameter 6 6 7 8
Duty-rate (ED%) 40 % 40 % 40 % 40 %
No. of starts per hour 240 240 240 240
Housing protection (IP) IP 44 IP 44 IP 44 IP 44
Control protection IP 65 IP 65 IP 65 IP 65
Classification M5 / 2m M5 / 2m M5 / 2m M5 / 2m
Insulation class F F F F
Net weight (kg) 32 36 38 76
Model DPT-30075 DPT-30151 DPT-30375 DPT-30750
Capacity (kg) 300 500 1000 2000
Pulling range (m) 28 43 43 68
Standard Control cable (m) 2 2 2 2
Operation voltage / single phase 400V 400V 400V 400V
Cycle (hz) 50-60 Hz 50-60 Hz 50-60 Hz 50-60 Hz
Power output (watt) 750 1500 2250 3750
Pulling speed (m/min) 14.1 18.9 12.9 17.4
Wire rope diameter 7 8 10 12
Duty-rate (ED%) 40 % 40 % 40 % 40 %
No. of starts per hour 240 240 240 240
Housing protection (IP) IP 44 IP 44 IP 44 IP 54
Control protection IP 65 IP 65 IP 65 IP 65
Classification M5 / 2m M5 / 2m M5 / 2m M5 / 2m
Insulation class F F F F
Net weight (kg) 38 76 152 364
Model DPT-31500 DPT-34000
Capacity (kg) 3000 5000
Pulling range (m) 68 68
Standard Control cable (m) 2 2
Operation voltage / single phase 400V 400V
Cycle (hz) 50-60 Hz 50-60 Hz
Power output (watt) 5620 7500
Pulling speed (m/min) 19.7 12
Wire rope diameter 16 20
Duty-rate (ED%) 40 % 40 %
No. of starts per hour 240 240
Housing protection (IP) IP 54 IP 54
Control protection IP 65 IP 65
Classification M5 / 2m M5 / 2m
Insulation class F F
Net weight (kg) 391 472
9
3.2.3 electric winch dimensions
Model A B C D E J K L M N O
DPS-200 125 246 164 261 201 49 41 155 160 7 -
DPS-250 160 265 164 261 201 49 41 155 160 7 -
DPS-300 160 279 164 261 201 49 41 155 224 7 -
DPS-500 246 272 180 285 310 49 41 260 305 8 -
DPT-30075 160 279 164 261 201 49 41 155 224 7 -
DPT-30151 246 272 180 365 310 49 41 260 305 8 -
DPT-30375 340 383 360 365 400 39 30 350 510 14 -
DPT-30750 378 524 436 520 590 39 30 540 525 14 85
DPT-31500 378 580 436 520 590 45 35 540 525 14 85
DPT-34000 510 694 436 520 590 55 38 540 660 14 85
10
3.3 Main Characteristics
DPS / DPT winches are suitable for pulling applications. If used for lifting purposes,
please contact a professional and carry out a risk analysis. Also any modifications made on
the electric pulling winch is the sole responsibility of the user / owner. will not be
responsible for any problems caused by modifications, wrong use, or any other abnormal
situation.
DPS / DPT winches are suitable for industrial use.
230 / 400 volt pendant control with emergency stop button.
Permanently lubricated transmission, ensures smooth and quiet operation.
Mechanical brake, achieves immediate braking and holds the load in an event of power
failure.
Deliver ready to use with control switch, power cable and steel cable with hook.
Complies with the Machinery Directive 2006/42/EC
Note: without overload protection, from 1 ton digital overload protection optional.
3.4 Machine classification and period of use
Identify the normal use of the product, in order to ensure the safety and service life. electric
winch is suitable for the ISO/JIS and FEM classification.
3.4.1 ISO/JIS Classification
Average Daily Operating Time (Hour)
Load
Spectrum
Cubic Mean
Value
≤0.12 ≤0.25 ≤0.5 ≤1 ≤2 ≤4 ≤8 ≤16
Light K ≤ 0.125 / / M1 M2 M3 M4 M5 M6
Moderate 0.125 < K ≤ 0.25 / M1 M2 M3 M4 M5 M6 /
Heavy 0.25< K ≤ 0.50 M1 M2 M3 M4 M5 M6 / 1
Very
Heavy
0.50< K ≤ 1.00 M2 M3 M4 M5 M6 / 1 1
3.4.2. Fem Classification
Average Daily Operating Time (Hour)
Load
Spectrum
Cubic Mean
Value
≤0.12 ≤0.25 ≤0.5 ≤1 ≤2 ≤4 ≤8 ≤16
L1 K ≤ 0.5 / / 1Dm 1Cm 1Bm 1Am 2m 3m
L2 0.50<K ≤ 0.63 / 1 Dm 1Cm 1Bm 1Am 2m 3m 4m
L3 0_63<K ≤ 0.80 1Dm 1Cm 1Bm 1Am 2m 3m 4m 5m
L4 0.80<K ≤ 1.00 1Cm 1Bm 1Am 2m 3m 4m 5m /
11
4. Safe operation
4.1 Declaration
Exceeding the rated capacity of the electric pulling winch will lead to dangerous situations.
Before operation, please read all the contents of this manual, please make sure that you understand
all items, if so then you may operate the winch. Before operating the electric winch, please
make sure the work space, structures meet all the safety requirements. Also the capacity must be even
or higher as the rated WLL. Also adhere to any standard or rules which applies. Always use common
sense and make sure that pulling / hoisting procedure is followed closely when winches put in use.
Always keep an eye at the load and its environment.
4.2 Install and test
Put the winch into a reliable frame, and make sure that the power supply is correct, then push the pull
and release button of the pendant control, observe the winch for correct functioning.
4.3 Test before operation.
Before operation of the winch, always test it for correct functioning without load. If it runs
normally, winch may be used with load. Always check the brake by performing a small test, where
the load is suspended (full capacity), the brake must keep the load.
4.4. Inspection
To ensure continuous and satisfied functioning of the electric pulling winch, it must be
inspected on a regular basis. Let professionals inspect the winch and change any broken parts
if needed, to prevent potential danger.
The inspection interval is determined by the usage and must be done regularly. Always check the
winch and wire rope for any kind of wear, damage, rust or any other form of damage. This must be
taken seriously. Always control key parts and perform test on a regular basis. The inspection type is
separated as daily inspection and periodic inspection.
Daily inspection: Before daily use, operator should always perform a visual inspection to prevent
any surprises. This must be logged in a logbook.
Periodic Inspection: Check by a professional according to the user work situation. This must be
logged in a logbook.
12
5. Installation
5.1 Pre installation check
CAUTION Check electric winch for transit damage.
WARNING Check that all fasteners and joints on the electric winch are tight and
secure.
WARNING Always make sure that the capacity of the bottom hooks corresponds with the
electric winch.
WARNING Always check and inspect the wire rope on wear, corrosion or any other type of
damage. The wires may not be broken, If detected, please put the electric
winch out of use. A professional must replace the load before any further use.
CAUTION Check that all external wiring is in good order.
WARNING Always check the weight of load and make sure that it does not exceed the safe
working load of electric pulling winch.
CAUTION Inspect the engine (chamber), it needs to be clean and dry. Also make sure that
the electric winch is protected against any form of humidity.
CAUTION Make sure that the winch and steel wire is free of obstructions.
The following environmental conditions will result to winch failures:
Low temperatures below – 10 °C
High temperatures above 40 °C In organic, chemical or explosive atmospheres.
In wet conditions In heavy dusty conditions
5.2 Mounting holes of electric pulling winch
DANGER The mounting plate/underground should have enough capacity to hold the
maximum safe working load of the electric winch. It is always
recommended to include a generous safety factor. Always make sure that all
holes are used and make sure that bolts and nuts are secured tightly.
The winch is designed to be mounted on a firm or stable flat underground / plate.
Dimensions can be found in section 3.2.3
13
5.3 Initial lubrication
The following lubrication guidelines must be carried out before the electric winch is put into use. (or
use an equivalent.)
Model DPS.200 DPS.250 DPS.300 DPS.500 DPT.30075
Lifting capacity (kg) 200 250 300 500 300
Duty Cycle 40%
Voltage (v) 230 230 230 230 400
IP rating 44 44 44 44 44
Lubricant of gearbox Recommended SHELL Gadus S3 V220C 2 grease or equilavant
Lubricant quantity gearbox 0.5 lt 0.5 lt 0.5 lt 0.75 lt 0.5 lt
Lubrication period 6 months or 240 working hours
Lubricant of wire rope Recommended SAE 30 motor oil or equilavant
Lubrication Heavy Service: daily / Normal: weekly / Infrequent: Monthly
Model DPT.30151 DPT.30375 DPT.30750 DPT.31500 DPT.34000
Lifting capacity (kg) 500 1000 2000 3000 5000
Duty Cycle 40%
Voltage (v) 400
IP rating 44 54 54 54 54
Lubricant of gearbox Recommended SHELL Gadus S3 V220C 2 grease or equilavant
Lubricant quantity gearbox 0.75 lt 2.3 lt 3 lt 3 lt 3 lt
Lubrication period 6 months or 240 working hours
Lubricant of wire rope Recommended SAE 30 motor oil or equilavant
Lubrication Heavy Service: daily / Normal: weekly / Infrequent: Monthly
5.4 Connection to electrical supply
An adequate electricity supply system is required along the total length of travel(where appropriate).
The supply voltage and frequency at which the winch operates is marked on the motor rating plate. It
is Imperative to check before connecting the unit that these figures correspond with those of the
supply voltage.
5.5 Starting
When installation is completed, the following procedure should be carried out:
1. Isolate the power supply.
2. Check that all mechanical and electrical joints and connections are tight and secure.
3. Switch on power supply.
4. Operate the electric winch and check that the operation is smooth at all times.
5. Check the brake, under light and full load conditions.
6 Always check the correct functioning of the emergency stop.
DANGER
Emergency procedure: In the event of a blocked steel wire or any other
malfunction of electric pulling winch, immediately stop the maneuverer
without attempting any further actions. Immediately set up a safety perimeter
around the winch and the load to prevent access by any unauthorized persons.
Call in the necessary personnel to remove the load and intervene on the winch.
14
6. Operation
6.1 Selection and qualification of operating personnel
For independent operation or maintenance of electric puling winch, the operator must meet
the following requirements:
CAUTION At least 18 years of age.
WARNING Mentally and physically capable.
WARNING Have been instructed in the operation or maintenance of the electric
winch and have proven their qualification in this aspect(In addition to
theoretical training, instruction should also include sufficient practical operating
experience as well as acquisition of ability to identify defects which are hazards
to safe operation).
WARNING Can be expected to carry out the work assigned to them reliably. The person in
charge must assign operating and maintenance personnel to their relevant tasks.
6.2 Operating safety instructions
CAUTION The winch should be operated only by designated and trained
operators.
WARNING Always wear the necessary protective gear.
WARNING The operators should not engage in any other practice which will divert his
attention while actually engaged in operating the winch.
CAUTION If unsafe conditions exist, the operator should have the authority to refuse to
handle any loads until safety has been reassured.
DANGER Always use structures and additional pulling - lifting equipment that has the
correct safe working load and make sure that a generous safety factor is
included.
DANGER Always make sure that the load does not exceed the rated capacity.
DANGER For points fitted with warning alarm, it should be sounded each time before use
/ travelling; and intermittently during travel particularly when operator or other
personnel is approached. If not, the user is responsible to inform everyone when
winch is operated.
DANGER Always check the winch, steel wire and hook prior to use, it needs to be in good
condition. Otherwise put the winch out of service and inform your dealer.
WARNING Before leaving a winch unattended, the operator should release the tension or
lower any goods. It may never be left under tension.
CAUTION At the start of each shift, the operator should check the operation of each mode
pulling and releasing.
DANGER All loads should be securely hitched and properly balanced before a pull/lift is
made.
DANGER Winch and wire rope should be continually inspected for wear or any other kind
of damage that could make them unsafe to work with.
WARNING The wire rope must be in a straight line from the load hook to the suspension
point before the pull/lift is performed.
DANGER Pulling, lifting people or riding on the hook, slings or load is dangerous and
strictly prohibited
WARNING When pulling or lifting, ensure that the load does not have any obstructions.
DANGER Loads should not pass over the heads of personnel or in any way. This is strictly
prohibited, while it endangers the safety.
WARNING Never apply side pull.
15
To pull a load, press up button
Uneven winding of the wire rope will cause
load to swing and in result damaging the wire
rope.
To release a load, press down button
DANGER When the weight is near the rated capacity, the user should test the brake each
time when such load is handled. By lifting the load with a short distance. If used
for lifting purposes, please contact a professional and carry out a risk analysis.
Also any modifications made on the electric pulling winch is the sole
responsibility of the user / owner. will not be responsible for any
problems caused by modifications, wrong use, or any other abnormal situation.
DANGER Emergency procedure: In the event of a blocked steel wire or any other
malfunction of electric pulling winch, immediately stop the maneuverer
without attempting any further actions. Immediately set up a safety perimeter
around the winch and the load to prevent access by any unauthorized persons.
Call in the necessary personnel to remove the load and intervene on the winch.
WARNING Stop operation if there is any abnormal noise or vibrations in the gear box.
WARNING Do not connect the with the grounding of the welding machine.
WARNING Be sure not to operate with slackened wire rope. Always wind wire rope tightly.
WARNING Check the winch and make sure that the wire rope around the drum is even.
CAUTION Be sure to fix a rope in the centre of the swivel hook
WARNING When wire rope become fully stacked, stop operation immediately.
CAUTION Avoid contact with obstacles, so make sure that the load / wire rope / hook does
not make any contact.
CAUTION Always leave/store the push button control in a correct manner after use.
WARNING Always ensure that the load is well balanced and secured before operation.
16
7. Maintenance
7.1 Maintenance Schedule
Time interval Inspection or maintenance
Daily or start of each
shift (Visual)
Brake – functioning
Motor – functioning
Pendant control – functioning
Wire rope – kinks, abrasions, corrosion, broken wires, improper
spooling
Wiring- fraying, defective insulation
Hook block – safety latch, swivel bearing
Monthly
Electric Control - External Breakage Push Buttons Panel/Cable
Brake Disc - Slippage, Glazing, Contamination, or Excessive Wear
Wire Rope - Lubrication, Securing Elements (Thimble, Ferrule)
Each 6 months
Hook Block - Distortion
Drum - Set Screw, Distortion, Cracks, or Excessive Wear
Leakage - Gearbox
Annually
Complete Inspection
Fastening - Loosening
Brake Spring - Breakage
Gearbox - Gears, Welding, Shafts
7.2 General rules
Wrong maintenance will lead to human injuries or dangerous accidents, only qualified persons are
allowed to maintain the electric winch, if you are not qualified, please contact your dealer.
CAUTION Forbidden to use the winch which is under maintenance / service.
CAUTION If any abnormal behaviour of the winch is found before, during and after
operation, please contact a professional and inspect the winch.
CAUTION Don’t leave the winch suspended or store it with suspended load.
CAUTION Clean the winch from any kind of dirt.
CAUTION Store the winch in a place where it is clear and dry
WARNING Please make sure that the steel wire is never twisted or knotted.
WARNING Please maintain the steel wire carefully, which includes correct operation,
good maintenance and inspection. Never use steel wire which has forms of
damage.
CAUTION Do not repair steel wire, replace it.
WARNING
Professionals must inspect and maintain the winch regularly,
otherwise, please contact your dealer to inspect and service the electric
winch.
Daily inspection: Before daily use, operator should always perform a visual inspection to prevent
any surprises. This must be logged in a logbook.
Periodic Inspection: Check by a professional according to the user work situation. This must be
logged in a logbook.
17
7.3 Wire rope replacement
Wire rope needs to be replaced immediately when one of the following is detected.
1. Wire rope has kinks
2. Wire rope shows distortion
3. Wire rope shown signs of corrosion
4. Wire rope shows signs of excessive wear
where 1 of the strands is damaged and has more
than 3 of the 19 wires damaged.
When replacing wire rope, check for wear on parts, i.e. drum, set screw, hook block and replace
if necessary.
Removing old wire rope:
1. Disassemble the hook from wire rope (thimble end).
2. Carefully pull the wire rope by rotating the drum.
3. Remove the set screw of drum and pull the wire rope (ferrule end) out of the drum
Insalling new wire rope
1. Insert wire rope (ferrule end) into the hole and tightly fix it with a set screw
2. Carefully and tightly wind the wire rope in order by rotating the drum.
3. Assemble the hook block to the wire rope (thimble end)..
Warning: Always leave a minimum of 3 wraps of wire rope around the drum to support the
rated load.
7.4 Initial lubrication
Winches do not require the initial lubrication but this should be checked on a regular basis. The re-
lubrication interval depends on the service and is recommended as following (use this oil or a
equilavant):
Model DPS.200 DPS.250 DPS.300 DPS.500 DPT.30075
Lubricant of gearbox Recommended SHELL Gadus S3 V220C 2 grease or equilavant
Lubricant quantity gearbox 0.5 lt 0.5 lt 0.5 lt 0.75 lt 0.5 lt
Lubrication period 6 months or 240 working hours
Lubricant of wire rope Recommended SAE 30 motor oil or equilavant
Lubrication Heavy Service: daily / Normal: weekly / Infrequent: Monthly
Model DPT.30151 DPT.30375 DPT.30750 DPT.31500 DPT.34000
IP rating 44 54 54 54 54
Lubricant of gearbox Recommended SHELL Gadus S3 V220C 2 grease or equilavant
Lubricant quantity gearbox 0.75 lt 2.3 lt 3 lt 3 lt 3 lt
Lubrication period 6 months or 240 working hours
Lubricant of wire rope Recommended SAE 30 motor oil or equilavant
Lubrication Heavy Service: daily / Normal: weekly / Infrequent: Monthly
18
7.5 Malfunctions and solutions
Malfunction Cause Solution
Winch will not
operate
Power failure Check circuits breakers, switches and connection
in power supply line.
Wrong voltage or
frequency
Check voltage and frequency of power supply
against the rating on the name plate.
Improper connection in
winch or push button
Check all connections at line connectors and
terminal block.
Motor brake does not
release
Check connections to the brake coil. Check for
open or short circuit. Check for burned contacts.
Faulty magnetic winch
control switch.
Check coils for open or short circuit. Check all
connections in control circuit. Check for burned
contacts.
Hook travel in wrong
direction.
Three phase reversal. Reverse any two wires (except green ground wire)
at the power source.
Improper connections. Check all connections against wiring diagram.
Hook will pull/raise
but will not release /
lower.
Lower electrical circuit
open.
Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
Contactor assembly not See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
Down, push button
inoperative.
Check push button contacts and wires.
Hook will release /
lower pull/raise but
will not pull/raise.
Overload. Reduce loading to rated load of winch, as shown
on nameplate
Winch electrical circuit
open.
Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
Contactor assembly not
functioning
See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
Down, push button
inoperative.
Check push button contacts and wires.
Winch will not lift
rated load.
Low voltage. See that power supply current is the same voltage
Iisted on motor data plate. Check winch motor
connections. Check size of power supply lines.
Winch motor
overheats
Overload. Reduce loading to rated load as shown on
nameplate.
Excessive duty-cycle. Reduce frequency of lifts or amount of jogging.
Wrong voltage or
frequency.
Check current rating on motor data plate against
power supply. Check einch and inspect for
defective, worn or damaged parts.
Defective motor or worn
bearings in winch frame.
Disassemble winch and inspect for defective, worn
or damaged parts.
Brake not adjusted
properly.
Adjust brake
Lack of proper lifting
speed
Excessive load. Reduce loading to rated load as shown on
nameplate.
Low voltage. Bring up voltage to plus or minus 10% of voltage
specified on winch. Line voltage should be
measured while winch is lifting load
19
Load drifts
excessively when
winch is stopped
Overload. Reduce loading to rated load, as shown on
nameplate.
Motor brake not holding With No Load, check winch for drift. If drifting is
excessive, inspect motor brake and adjust it.
Winch operates
intermittently
Loose connections Check all wiring for loose connections
Abnormal noise from
wirerope/drum.
Lake of lubrication, worn
wire rope/drum
Check all wiring for loose connections
DANGER
Emergency procedure: In the event of a blocked steel wire or any other
malfunction of electric pulling winch, immediately stop the maneuverer
without attempting any further actions. Immediately set up a safety perimeter
around the winch and the load to prevent access by any unauthorized persons. Call
in the necessary personnel to remove the load and intervene on the winch.
20
8 Spare parts & Diagram
CP.0.DPS.200 Exploded view
1 Screw 18 Fix pin 40 Screw
2 Motor 19 Bolt 41 Wire rope
3 Rack of motor cable 20 Bearing 42 R-type pin
4 Plastic box rack 21 Gear component 43 Hook
4-1 Terminal plate 22 Output shaft 45 Fix pin
4-2 Screw 23 Shaft 46 Power cable
4-3 Rectifier 24 Key 47 Screw
5 Plastic box rack 25 Bearing 48 Base of plastic tube
6 Screw 26 Bearing 49 Plastic tube
7 Bolt 27 Base of gear component 50 Switch connector
8 Bearing 28 Bearing 51 Fix plate
8-1 Link 29 Bearing 52 Fix plate
9 Main body(motor) 30 Gear box 53 Screw
10 Bolt 31 Screw 54 Screw
11 Drum 32 Base of brake coil 55 Switch button cover
12 Fix bar 33 Brake coil 56 Screw
13 Screw 34 Spring
13-1 Fix bar 35 Screw
14 Bearing 36 Gear reducer
15 Main body(gear) 37 Brake steel plate
16 Bearing 38 Brake disc
17 Gear 39 Brake cover
22
CP.0.DPS.250 Exploded view
1 Screw 18 Fix pin 40 Screw
2 Motor 19 Bolt 41 Wire rope
3 Rack of motor cable 20 Bearing 42 R-type pin
4 Plastic box rack 21 Gear component 43 Hook
4-1 Terminal plate 22 Output shaft 45 Fix pin
4-2 Screw 23 Shaft 46 Power cable
4-3 Rectifier 24 Key 47 Screw
5 Plastic box rack 25 Bearing 48 Base of plastic tube
6 Screw 26 Bearing 49 Plastic tube
7 Bolt 27 Base of gear component 50 Switch connector
8 Bearing 28 Bearing 51 Fix plate
8-1 Link 29 Bearing 52 Fix plate
9 Main body(motor) 30 Gear box 53 Screw
10 Bolt 31 Screw 54 Screw
11 Drum 32 Base of brake coil 55 Switch button cover
12 Fix bar 33 Brake coil 56 Screw
13 Screw 34 Spring
13-1 Fix bar 35 Screw
14 Bearing 36 Gear reducer
15 Main body(gear) 37 Brake steel plate
16 Bearing 38 Brake disc
17 Gear 39 Brake cover
24
CP.0.DPS.300
1 Screw 18 Fix pin 40 Screw
2 Motor 19 Bolt 41 Wire rope
3 Rack of motor cable 20 Bearing 42 R-type pin
4 Plastic box rack 21 Gear component 43 Hook
4-1 Terminal plate 22 Output shaft 45 Fix pin
4-2 Screw 23 Shaft 46 Power cable
4-3 Rectifier 24 Key 47 Screw
5 Plastic box rack 25 Bearing 48 Base of plastic tube
6 Screw 26 Bearing 49 Plastic tube
7 Bolt 27 Base of gear component 50 Switch connector
8 Bearing 28 Bearing 51 Fix plate
8-1 Link 29 Bearing 52 Fix plate
9 Main body(motor) 30 Gear box 53 Screw
10 Bolt 31 Screw 54 Screw
11 Drum 32 Base of brake coil 55 Switch button cover
12 Fix bar 33 Brake coil 56 Screw
13 Screw 34 Spring
13-1 Fix bar 35 Screw
14 Bearing 36 Gear reducer
15 Main body(gear) 37 Brake steel plate
16 Bearing 38 Brake disc
17 Gear 39 Brake cover
26
CP.0.DPS.500
1 Screw 21 Base of gear 41 Spring
2 Plastic box 22 Blot 42 Brake spring
3 Screw 23 Bearing 43 Brake cover
4 Terminal plate 24 Out put shaft 44 Screw
4-1 Rectifier 25 Fix pin 45 Screw
5 Screw 26 Bearing 46 Plastic tube base
6 Plastic box rack 27 Gear 47 Plastic tube
7 Power cable 28 Bearing 48 Pendant switch
8 Switch cable 29 Key 49 Switches
9 Motor 30 Gear component 50 Fix plate
10 Bolt 30-1 Link 51 Screw
11 Washer 31 Shaft 52 Screw
12 Screw 32 Key 53 Switch cover
13 Main body(Motor) 33 Bearing 54 Screw
14 Fix bar 34 Oil seal 55 Fix plate
15 Drum 35 Gear box 56 Screw
16 Wire rope 36 Screw 57 Screw
17 Hook 37 Brake Coil
18 R pin 38 Brake plate
19 Fix pin 39 Brake
20 Main body(Gear) 40 Brake disc
28
CP.0.DPT.30075
1 Screw 18 Fix pin 40 Screw
2 Motor 19 Bolt 41 Wire rope
3 Rack of motor cable 20 Bearing 42 R-type pin
4 Plastic box rack 21 Gear component 43 Hook
4-1 Terminal plate 22 Output shaft 45 Fix pin
4-2 Screw 23 Shaft 46 Power cable
4-3 Rectifier 24 Key 47 Screw
5 Plastic box rack 25 Bearing 48 Base of plastic tube
6 Screw 26 Bearing 49 Plastic tube
7 Bolt 27 Base of gear component 50 Switch connector
8 Bearing 28 Bearing 51 Fix plate
8-1 Link 29 Bearing 52 Fix plate
9 Main body(motor) 30 Gear box 53 Screw
10 Bolt 31 Screw 54 Screw
11 Drum 32 Base of brake coil 55 Switch button cover
12 Fix bar 33 Brake coil 56 Screw
13 Screw 34 Spring
13-1 Fix bar 35 Screw
14 Bearing 36 Gear reducer
15 Main body(gear) 37 Brake steel plate
16 Bearing 38 Brake disc
17 Gear 39 Brake cover
30
CP.0.DPT.30151
1 Screw 21 Base of gear 41 Spring
2 Plastic box 22 Blot 42 Brake spring
3 Screw 23 Bearing 43 Brake cover
4 Terminal plate 24 Out put shaft 44 Screw
4-1 Rectifier 25 Fix pin 45 Screw
5 Screw 26 Bearing 46 Plastic tube base
6 Plastic box rack 27 Gear 47 Plastic tube
7 Power cable 28 Bearing 48 Pendant switch
8 Switch cable 29 Key 49 Switches
9 Motor 30 Gear component 50 Fix plate
10 Bolt 30-1 Link 51 Screw
11 Washer 31 Shaft 52 Screw
12 Screw 32 Key 53 Switch cover
13 Main body(Motor) 33 Bearing 54 Screw
14 Fix bar 34 Oil seal 55 Fix plate
15 Drum 35 Gear box 56 Screw
16 Wire rope 36 Screw 57 Screw
17 Hook 37 Brake Coil
18 R pin 38 Brake plate
19 Fix pin 39 Brake
20 Main body(Gear) 40 Brake disc
32
CP.0.DPT.30375
1 Gear cover 15 Spring 32 Fix pin
1-1 Screw 16 Hexagon brake 33 Bearing
2 Solenoid valve 17 Screw 34 Nut
2-1 Screw 18 Hexagon brake disc 35 Main body of Gear
3 Screw 19 Base of gear 36 Fix bar
4 Base of solenoid Valve 20 Gear component 37 Drum
5 Brake component 20-1 Bearing 37-1 Bearing
5-1 Screw 20-2 Bearing 38 Fix bar
6 Spring 21 Bearing 39 Arbor
6-1 Screw 22 Gear 40 Main body of motor
7 Screw 23 Fix pin 41 Screw
8 Brake component 24 spring 42 Bolt
9 Bolt 25 Key 43 Motor
9-1 Bolt 26 Shaft
10 Brake component 27 Screw
11 Brake steel plate 28 Gear box
11-1 Brake component 28-1 Bearing
11-2 Spring 28-2 Bearing
12 Brake steel plate 29 Gear component
13 Fix bar 30 Bearing
14 Brake steel plate 31 Gear
34
CP.0.DPT.30750
1 Gear cover 15 Spring 32 Fix pin
1-1 Screw 16 Hexagon brake 33 Bearing
2 Solenoid valve 17 Screw 34 Nut
2-1 Screw 18 Hexagon brake disc 35 Main body of Gear
3 Screw 19 Base of gear 36 Fix bar
4 Base of solenoid Valve 20 Gear component 37 Drum
5 Brake component 20-1 Bearing 37-1 Bearing
5-1 Screw 20-2 Bearing 38 Fix bar
6 Spring 21 Bearing 39 Arbor
6-1 Screw 22 Gear 40 Main body of motor
7 Screw 23 Fix pin 41 Screw
8 Brake component 24 spring 42 Bolt
9 Bolt 25 Key 43 Motor
9-1 Bolt 26 Shaft
10 Brake component 27 Screw
11 Brake steel plate 28 Gear box
11-1 Brake component 28-1 Bearing
11-2 Spring 28-2 Bearing
12 Brake steel plate 29 Gear component
13 Fix bar 30 Bearing
14 Brake steel plate 31 Gear
36
CP.0.DPT.31500
1 Gear cover 21 Bearing 38 Spring
2 Brake component 22 Gear ass'y stage 2 39 Nut
3 Solenoid valve brake
link
23 Brake Shaft 40 Magnet plate w/ coil
4 Solenoid valve 23-1 Key 41 Bolt
5 Brake component 24 Nut 42 Fan
6 Base of solenoid Valve 24-1 Bearing 43 Nut
7 Screw 25 Main body of Gear 44 Motor cover
8 Brake component 25-1 Bearing
9 Brake component 26 Fix Bar
10 Brake steel plate 26-1 Bearing
11 Brake component 27 Drum
12 Brake steel plate 28 Main body of motor
12-1 Fix bar 29 Arbor
13 Brake steel plate 30 Bolt
14 Hexagon brake 31 Motor
15 Hexagon brake disc 32 Brake bracket
16 Base of gear 33 Brake disc
17 Bearing 34 Brake plate
18 Bearing 35 Lock
19 Gear ass'y stage 1 36 Brake shaft
20 Gear box 37 Magnet plate
38
CP.0.DPT.34000
1 Gear cover 21 Bearing 38 Spring
2 Brake component 22 Gear ass'y stage 2 39 Nut
3 Solenoid valve brake
link
23 Brake Shaft 40 Magnet plate w/ coil
4 Solenoid valve 23-1 Key 41 Bolt
5 Brake component 24 Nut 42 Fan
6 Base of solenoid Valve 24-1 Bearing 43 Nut
7 Screw 25 Main body of Gear 44 Motor cover
8 Brake component 25-1 Bearing
9 Brake component 26 Fix Bar
10 Brake steel plate 26-1 Bearing
11 Brake component 27 Drum
12 Brake steel plate 28 Main body of motor
12-1 Fix bar 29 Arbor
13 Brake steel plate 30 Bolt
14 Hexagon brake 31 Motor
15 Hexagon brake disc 32 Brake bracket
16 Base of gear 33 Brake disc
17 Bearing 34 Brake plate
18 Bearing 35 Lock
19 Gear ass'y stage 1 36 Brake shaft
20 Gear box 37 Magnet plate
Recommended