Delta CP.0.DPS Series User manual

Original instructions
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 afteruse. 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

8
3.2.2 electric pulling winch capacity per layer

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.

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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, checkforwear 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