5-201-013 h45p pro manual

OWNERS MANUAL
H45PRO Winch
Part No: 654001PRO, Pneumatic Freespool
654002PRO, Manual Freespool
200.12kN, (20,412kg) Single Line Pull
Superwinch Professional winch range
BS EN 14492-1
Superwinch Ltd
Union mine road, Pitts Cleave,
Tavistock, Devon. PL19 0NS.
Superwinch LLC
359, Lake Road, Dayville,
Connecticut, 06241-1551, U.S.A.
Tel: +44 (0) 1822-614101
Fax: +44 (0) 1822-615204
Tel: (0) 1.800.323.2031
Fax: (0) 1.860.963.0811
e-mail: [email protected]
e-mail: [email protected]
Page1 1ofof9 1
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5-201-013 Issue
Issue 11
5-201-013
Owners Manual
654001 PRO, Pneumatic Freespool.
654002 PRO, Manual Freespool.
These instructions cover kits from:
01/01/2011
01
INTRODUCTION
02
GENERAL SPECIFICATION DATA
03
WINCH INSTALLATION
04
MAINTENANCE AND USE
RUNNING-IN
MAINTENANCE AND SERVICING
WIRE ROPE
FREESPOOL USE
TIPS FOR EXTENDING THE LIFE OF YOUR WINCH
05
SPARES AND ACCESSORIES
06
WARRANTY
07
NOTES
For all your requirements please contact your Superwinch Agent
Page 2 of 2
5-201-013 Issue 1
01 INTRODUCTION
Thank you for purchasing a heavy duty hydraulic winch from Superwinch. It has been designed and manufactured to
meet BS EN14492-1, Winch Standard, and provide years of trouble free operation.
Please read and understand this Owners Handbook before using your winch. Your winch is a very powerful machine. If
used unsafely or improperly, there is a possibility that property damage or personal injury can result. We have included
several unique features in the winch to minimise this possibility, however, your safety ultimately depends on your caution
when using the product. Correct installation of your winch is a requirement for correct operation. Pay particular attention
to the winch installation section in this handbook.
Congratulations on your choice
These instructions are designed to assist skilled technicians in the efficient installation of a Superwinch, using the
appropriate trade tools. Superwinch reserves the right to alter model specifications without prior notice.
PLEASE RETAIN THIS HANDBOOK WITH THE WINCH
WARNINGS, CAUTION AND NOTES
These are given through these instructions in the following form:
WARNING: Procedures which must be followed precisely to avoid the possibility of personal injury
CAUTION: This calls attention to procedures which must be followed to avoid damage to components.
USAGE OF WINCH
This winch is designed for use in applications such as Pulling, Hauling, and other associated uses
IMPORTANT: Superwinch winches are not to be used to lift, support
or otherwise transport personnel. Any such use shall be considered
to invalidate the warranty And Superwinch shall not be responsible
for any claims arising from such use.
REPAIRS AND REPLACEMENTS
Before you contact Superwinch or you’re nearest Dealer, please have ready the following information: Kit No, Serial No
and Part No required.
POISONOUS SUBSTANCES
Many liquids and other substances used should under no circumstances be consumed, and should be kept away from
open wounds. These substances include (among others), hydraulic oil.
SYNTHETIC RUBBER
Many ‘O’ ring seals, flexible pipes and similar items, when subjected to fire or heat can become highly corrosive. Handle
with seamless gloves only. Should skin contact occur, remove contaminated clothing immediately and obtain medical
assistance without delay.
RECYCLING AND THE ENVIONMENT
It is illegal to dis pose of used oil in the ground, down sewers or drains or into waterways. Dispose of used oil through
authorised waste disposal contractors. If in doubt contact your local authority for advise on disposal facilities.
GENERAL DESCRIPTION
The winch is powered from a vehicle hydraulic system. See hydraulic requirements section. The drum can be
disengaged, to enable the rope to be pulled out easily and quickly. The winch is equipped with an adjustable freespooling
damper to help alleviate the possibility of wire rope over-run on the drum.
The automatic disc brake is housed at the hydraulic motor end. The brake will activate automatically to prevent the load
from causing the winch to ‘back-drive’. The brake itself is self adjusting for wear and is oil immersed for optimum heat
dissipation. The brake linings are of high performance non-asbestos material.
The winch is reversible with ‘power-in’ and ‘power-out’ via a directional control valve mounted on the vehicle or through a
handheld wander lead. The standard unit is supplied with clockwise drum rotation on ‘winch- in’ when viewed from the
gearbox end. The winch can be used in both ‘over-wound’ and ‘under-wound’ conditions, Superwinch recommends
‘under wound’ if possible.
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5-201-013 Issue 1
02
SPECIFICATION DATA
Gear Reduction:
Heavy Duty Planetary gearing for long, reliable life, 36:1.
Drum:
Heavy duty, cast drum, mounted on heavy duty roller bearings.
Braking:
Heavy duty multi disc brake unit gives full load holding.
Load Limiting:
Hydraulic system relief valve on vehicle hydraulics.
Rope Drum Cover:
Rope Drum Safety Guard, (Option).
Labelling:
Rating plate showing 1st layer and top layer figures.
H45P
Rated Line Pull, Bottom Layer
200.12kN (20,412 kg)
Line Speed, Bottom Layer No Load
7.36 m/min
Rope Diameter, Recommended
20 mm, Compacted
Rope Length, Maximum
60 m
Drum Dimensions
195mm dia x 297mm
long, 455mm flanges
Weight, Excluding Wire Rope
199 kg
H45P
Maximum Oil Pressure
207 bar, (3000psi)
Maximum Recommended Oil Flow
95 l/min
Line Pull, 2nd Layer
168.7 kN, (17,210 kg)
Line Pull, 3rd Layer
145.95 kN, (14,885 kg)
Line Pull, 5th Layer, Top
114.9 kN, (11,720 kg)
NOTE: To meet the European / PRO, Standard, the Wire Rope must
have a minimum break figure of: 400.25kN (40,825 kg).
The Superwinch H45 PRO, heavy duty hydraulic, planetary drive, winch is available in our standard
configuration, or with manually operated freespool, please contact your distributor or Superwinch for details.
Description;
H45PRO winch, Pneumatic Freespool
H45PRO winch, Manual Freespool
Part No:
654001
654002
OPTIONAL ACCESSORIES
Roller Fairlead
Cable Tensioner, pneumatic
Cable Tensioner, spring type
Wire rope, 20mm x 60mtr
Page 4 of 4
254001
5683
254003
5-201-013 Issue 1
03
WINCH INSTALLATION
L
53.5mm to Cut-Out
at Front
Winch shown without Drum Safety Guard for clarity
DETAIL OF WINCH FIXING
AT OUTER END OF
MOUNTING ANGLE
4 PLACES SCALE, 3:1
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
Superwinch, H45P winch
Heavy Duty Planetary drive
Hydraulic Winch, 200 kN (20400kg)
VIEW OF UNDERSIDE OF WINCH SHOWING MOUNTING HOLES: 'A'
Detail of winch fixing at outer end of
Mount angles. 4 places. scale, 5:1
It is important that the outer, (Through holes), are bolted down as shown,
at each end of the mount angles. All fixing nuts, bolts, washers to be:
M16 thread, 12.9 tensile, tightened to 340 Nm.
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5-201-013 Issue 1
04
MAINTENANCE AND USE
WIRE ROPE SPECIFICATION:
The rope must be of good quality, have a steel core and meet the specification detailed on the certificate of conformity.
Avoid pulling a load at more than 15 degrees angle in relation to the winch. This will reduce wear and tear on the winch
and the cable.
WIRE ROPE INSTALLATION:
1/
Unwind the cable by rolling it out along the ground with the tapered end nearest to the winch. NEVER wind the
cable straight onto the drum from a coil.
2/
Raise the cable tensioner, (if fitted), away from the rope drum and lock in position.
3/
Rotate the rope drum under power until the rope fixing holes run vertically at the front of the winch.
4/
Pass the rope end through the roller fairlead, under the drum and back over the top of the drum to pass through
the rope hole furthest away from the drum flange. Keep feeding the rope through to wrap around the drum FOUR TIMES
and into the rope fixing hole nearest the drum flange.
5/
Tighten the retaining screw ensuring that the rope end is flush with the exit hole and not protruding.
6/
Feed back any excess slack rope to tighten the four wraps neatly on the drum.
7/
Lower cable tensioner to allow the roller / skid plate to rest on the rope.
8/ Apply moderate tension to the rope. Take care to ensure the layers are neatly
wrapped, as this will minimise damage to the lower layers of rope when a load is applied
PULLING OUT THE ROPE, Using Freespool.
Dis-engage the freespool, with a pair of gloves on pull out the rope and secure to the anchor or load. Re-engage the
freespool.
FREESPOOL OPERATION, Manual.
When wire rope is removed from the drum, as in bringing the hook to the load, the freespool feature on the winch may be
used.
To Engage: Turn the freespool handle to the ‘engage’ position.
To Disengage: Pull and Turn the freespool handle to the ‘disengage’ position.
REMOTE FREESPOOL OPERATION, Pneumatic.
Move the pneumatic freespool control lever to the free position.
Pull out the wire cable but leave at least 5 wraps on the rope drum.
Attach to the load.
Engage the rope drum by moving the freespool control lever to the fixed / locked position. The freespool will spring return
but the rope drum may have to be rotated a little gently under power.
DO NOT ATTEMPT to pull a load until the drum is fully engaged.
Operate the winch.
Page 6 of 6
5-201-013 Issue 1
04
MAINTENANCE AND USE
RUNNING–IN
Ensure your winch has been filled with the correct oil before proceeding.
For optimum performance and life, all hydraulic motors should be run-in. Run motor for approximately 1 hour at 30% of
maximum oil pressure, (this is the advice of most hydraulic motor manufacturers).
MAINTENANCE
Manual Freespool Handle: Lubricate regularly with light oil.
After the first hour of operation:
Change the gearbox oil. Check tightness of mounting bolts and hydraulic connections.
Monthly:
Check the oil level, located on the gearbox end of the winch.
After 10 hours of operation or annually:
Change the gearbox oil, (approximately ¾ litre). Check tightness of mounting bolts and hydraulic connections.
The winch is delivered from the factory filled with the correct type and quantity of oil. The oil specification recommended
is: BP ENERGOL GR-XP150 or equivalent, using approximately ¾ litre.
SERVICING
Before you contact Superwinch or your nearest dealer for parts etc, please have ready the following information:
* Kit No
* Serial No of Winch
* Part No required, (if known)
When ordering spare parts from the parts list always quote the winch serial No and part No (not item No)
TIPS FOR EXTENDING THE LIFE OF YOUR WINCH
1/
Note: Installing the wire rope is not included in the running-in period. Check tightness of all mounting bolts after
running-in period.
2/
Keep a tightly wound wire rope. Do not allow the windings on the drum to become loosely wound. A loosely
wound spool allows a rope under load to work its way down into the layers of the wire rope on the drum. When this
happens, the lower layers become damaged and the rope may become wedged within the body of the windings. To
prevent this problem, keep tension on the rope at all times. A good practice is to rewind the rope under tension after each
use.
3/
Prevent kinks before they occur.
(a)
This is the start of a kink. At this time the rope should be straightened
(b)
The rope was pulled and the loop has tightened to a kink, the rope is now
permanently damaged
Page 7 of 7
(c)
The result of kinking is that each strand pulls a different amount causing the
strands under greatest tension to break and reduce load capacity of the wire
rope.
4/
Use a snatch block for heavy loads. To keep wear to a minimum, use a
snatch block to double line heavy loads. Double lining reduces the work
required of the winch by one half, which in turn reduces wear.
5/
The pull required to start a load moving is often much greater than the load
to keep it moving, try to avoid stopping and starting during a pull.
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H45 PRO, Part No: 654001/2 PARTS LIST
Item
Description
Pt No
Qty
Item
Description
Pt No
Qty
1
2
3
(3)
4
5
6
7
8
9
10
11
Hex Hd Bolt, M12 x 150
Spring Washer, M12
Freespool Assy, Pneu,
Freespool Assy, Manual
Thrust Pad
Input Gear
Bush
Sun Gear
st
Planet Carrier, 1 Stage
Thrust Washer, bronze
Ring Gear
‘O’ Ring
4-33-1215022
4-51-1223
54-90647
54-90218
54-50256
54-50020
4-10-2529253
54-50019
54-90082
54-50011
54-54078
4-21-8053
6
6
1
(1)
1
1
1
1
1
3
1
2
12
13
14
15
16
17
18
19
20
20
21
22
Roll Pin, 10 x 40mm
nd
Planet Carrier, 2 Stage
Gear Housing Assy
Input Drive Shaft
Rope Drum Assembly
Coupling, Input Drive Shaft
Coupling, Brake Assembly
Motor / Brake Mount
Mount Angle, Front
Mount Angle, Rear
Motor / Brake Assembly
Housing / Mount Spacer
4-56-104003
54-90083
54-90723
54-50261
54-90725
54-50254
54-50255
54-90724
54-52326
54-52327
54-90722
54-52328
6
1
1
1
1
1
1
1
1
1
1
4
Switching Mount Angles from front to back:
The H45 hydraulic planetary drive winch is supplied with two heavy duty mounting angles, one with deep cut-out and one
with shallow cut-out, It is important that the mounting angle with shallow cut-out is mounted at the rear
of the winch, (it will depend on how the winch is mounted which side is the rear), it is permissible to
switch these mounting angles if necessary, to suit your application. The following notes will help:
If removing the Mounting Angles to switch from front to back, the winch will consist of three separate parts, the gearbox,
the motor assembly and the rope drum, these three parts must not be separated.
Place the winch on a flat surface, (bench etc), firstly, remove the four countersunk M16 screws from the underside of the
mounting angles, it will be necessary to tilt the winch backwards to access the front screws and forwards to gain access
to the rear screws, (do not lift the winch). Place winch flat on bench etc, loosen all the remaining M16 hexagon bolts
before removing them, without separating the winch, pull mounting angles away from the centreline of the winch, (do not
slide winch off the mounting angles lengthwise). Tilt winch from side to side to position the mounting angles, fit all M16
hexagon bolts, tilt winch and fit four countersunk screws and tighten, (220 Nm), lay winch flat on bench and tighten all
M16 hexagon bolts, 220 Nm to 240 Nm.
Note: Tilting the winch backwards and forwards will allow one side of the winch to always be in contact with the bench,
this will lessen the chance of the three parts of the winch separating.
All nuts and bolts holding the winch parts together are 8.8 tensile grade or higher.
Page 8 of 8
5-201-013 Issue 1
SUPERWINCH LIMITED WARRANTY VALID WORLD WIDE
06
Limited Warranty. Superwinch (seller), warrants the original buyer, (you) all parts and components except wire rope to be free from
defects in materials and workmanship for a period of (one), 1, year from the provable date of purchase. Any Superwinch product
which is defective will be repaired or replaced without charge to you, upon compliance with these procedures. The warranties set
forth herein are exclusive and in lieu of all other warranties, whether oral or written, express or implied.
Limited Warranty Performance Procedure. Upon discovery of a defective Superwinch product, you shall mail to the seller at his
factory or any factory authorised service centre written notice of such defect and mail, ship or otherwise deliver the defective
Superwinch, postage or shipping prepaid. Repairs or replacements by seller under this Limited Warranty will normally be
accomplished within, (fifteen), 15 business days after receipt of the defective Superwinch. Seller or its authorised agents may make
reasonable charges for parts and labour not covered by this Limited Warranty.
Warranty and Remedy Limitations and Exclusions. Repairs and/or replacement of the defective Superwinch or component thereof as
provided herein is the exclusive remedy for the buyer. The following Exclusions or limitations of warranties and limitations of
remedies shall be expressly applicable:
A.
Express Warranties. Seller warrants that the Superwinch is as described in the “Superwinch Owners Manual” provided
herein; no other express warranty is made in respect to the Superwinch. If any model or sample was shown to the buyer, such model
or sample was used for illustrative purposes only and shall not be constructed as a warranty that the Superwinch will conform to the
sample or model. Seller makes no express warranty with respect to wire rope incorporated in the product.
B.
Implied Warranties. The implied Warranty of merchantability and all other implied warranties shall only extend from the
provable date of purchase for (one), 1 year. The wire rope is sold “as is”, without any implied warranties. Some States within the
USA do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
C.
Incidental and consequential Damages. Subject to the sellers Limited Warranty obligations set herein, seller shall not be
responsible for incidential damages to property, loss of profit and loss of use which may be caused by any defect in, or malfunction,
or failure of enclosed Superwinch. Some states within the USA do not allow exclusion or limitation of incidential or consequential
damages, so the above may not apply to you.
d.
Condition or Warranty. Seller shall not be required to comply with its warranty duties provided herein if the defect,
malfunction, or failure of the Superwinch was caused by damage (not resulting from defective or malfunctioning components), or
unreasonable use by you. Unreasonable use shall include but is not limited to, installation or use of the Superwinch without
compliance with the instructions contained in the Superwinch Owners Manual for the particular model number. Sellers liability under
this warranty or for any loss or damage to the Superwinch product shall not exceed the cost of correcting defects in or replacing the
Superwinch product, and upon expiration of the warranty period, all such liability shall terminate. The agents, dealers and employees
of the seller are not authorised to make modifications to this warranty, or additional warranties binding on the seller. According
additional statements, whether oral or written, do not constitute warranties and should not be relied upon.
Legal Remedies of buyer. This Limited Warranty gives you the specific legal rights, and you may also have other rights which vary
from state to state within the USA and from country to country. You may also have implied warranty rights. In the event of a problem
with Limited Warranty service or performance, the buyer may be able to go to small claims court, a state court or a federal court in
the USA or to appropriate jurisdictions outside the USA.
Inquiries. Any enquiries regarding compliance with the warranties provided herein may be addressed in writing to:
Superwinch Ltd
Union mine road, Pitts Cleave,
Tavistock, Devon. PL19 0NS.
Superwinch LLC
359, Lake Road, Dayville,
Connecticut, 06241-1551, U.S.A.
Tel: +44 (0) 1822-614101
Fax: +44 (0) 1822-615204
e-mail: [email protected]
Tel: (0) 1.800.323.2031
Fax: (0) 1.860.963.0811
e-mail: [email protected]
Design, materials and specifications are subject to change without notice. Superwinch is not responsible for printing errors
inadvertently made in the production of this catalogue.
The pictures are for illustrative purposes only and the products and accessories will vary between countries.
Superwinch Ltd. Union Mine Road, Pitts Cleave, Tavistock, Devon. PL19 0NS Tel: 01822 614101 Fax: 01822 615204
Email: [email protected]
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5-201-013 Issue 1