5-201-007 iss 1 - h30 pro manual 5-201-007 issue 1...owners manual 5-201-007 issue 1 page 6 03 winch...

Owners Manual 5-201-007 Issue 1 1Page

Superwinch LTD.Union Mine Road, Pitts Cleave

Tavistock, Devon. PL19 0NS

Tel: +44 (0) 1822 614101

Fax: +44 (0) 1822 615204

E-mail: [email protected]

Superwinch LLC.Winch Drive, Putnam

Connecticut 06260 U.S.A.

Tel: 01 800 323 2031

Fax: 01 860 963 0811


w w w . s u p e r w i n c h . c o m

EN 14492-1EN 14492-1

OWNER’S MANUALH20PRO / H25PRO / H30PRO

HYDRAULICALLY POWERED WINCHES

Winch shown for

illustration purposes only


Owner’s Manual

5440Pro - H20P Winch, Air Clutch



These instructions cover kits from:

01/01/2010

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

For all your requirements please contact your Superwinch agent

i


Thank you for purchasing a heavy duty series

hydraulic winch from Superwinch. It has been

designed and manufactured to meet BS EN14492-1,

Power Driven Winches 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 in order to avoid the possibility of

personal injury.

CAUTION : This calls attention to procedures

which must be followed to avoid damage to

components.

NOTE : This calls attention to methods which make

a job easier or gives helpful information.

USAGE OF WINCH

This winch is designed for use in applications such as Pulling,

Hauling, and other associated uses.

REPAIRS AND REPLACEMENTS

Before you contact Superwinch or your 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 (amoung 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. Meanwhile, wash the affected area

with copious amounts of cold water or limewater for 15 to 60

minutes.

RECYCLING AND THE ENVIRONMENT

It is illegal to dispose 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 advice 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.

01INTRODUCTION

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.


Model: H20P H25P H30P

Part No. 5440Pro 5450Pro 5460Pro / 5461Pro

Rated Line Pull, Bottom Layer 89.0kN (9,080 kg) 111.2kN (11,340 kg) 133.4kN (13,610 kg)

Line Speed, Bottom Layer No Load 12.2 m/min, (average) 10.4 m/min, (average) 9.3 m/min, (average)

Rope Diameter, Recommended 16 mm 18 mm 20 mm

Rope Length, Maximum 69 m 49 m 45 m

Drum Dimensions 195mm dia x 297mmlong 195mm dia x 297mm long 195mm dia x 297mm long

Weight, Excluding Wire Rope 198 kg 198 kg 198 kg

Maximum Oil Pressure 172 bar (2,500psi) 172bar (2,500 psi) 172 bar (2,500 psi)

Maximum Recommended Oil Flow 75 l/min 75 l/min 75 l/min

Line Pull, 2nd Layer 77.3 kN (7,890 kg) 95.2 kN (9,710 kg) 112.6 kN (11,490 kg)

Line Pull, 3rd Layer 68.3 kN (6,970 kg) 83.2 kN (8,490 kg) 97.4 kN (9,935 kg)

Line Pull, 4th Layer 61.2 kN (6,245 kg) 73.9 kN (7,540 kg) 85.7 kN (8,750 kg

02 SPECIFICATION DATA

Gear Reduction: Heavy Duty Planetary gearing for long, reliable life.

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.

Labelling: Rating plate showing 1st layer and top layer figures. Roller Fairlead warning label.

The Superwinch Pro Series H20P / H25P / H30P heavy duty hydraulic, planetary drive, winch range is available in our

standard configuration, or with manually operated freespool, please contact your distributor or Superwinch for details.


03SYSTEM INSTALLATION

WINCH INSTALLATION

Correct instalation of your winch is a requirement for correct

operation.

When foot mounting the winch, the surface must be flat within

0.5mm, (0.020") and sufficiently stiff to prevent flexing. A

minimum of 8mm, (5/16"), thick steel plate should be used.

The thicker the plate, the better the alignment between motor

mount, drum and gearbox housing.

Refer to Hydraulic System Specification.

IMPORTANT: It is vital to ensure that all hose lengths are

kept to a minimum. Pressure and flowloss is increased as hose

length increases and/or bore size decreases. Pressure and

return lines in excess of 3.5 meters (11.5’) should be

compensated with an increase in nominal bore size.

HYDRAULIC SYSTEM

System Type: Open system with filtered return line

Relief Valve: IMPORTANT - Set at winch operating

pressure

Pump: With a maximum oil supply of 75 l/min at top motor

rpm. The pump must be capable of delivering a pressure of

190 bar.

Reservoir: Must be fitted with an oil filter device comprising

strainer and air filter and a dip stick. The capacity of the tank

should be at least 75 litres (20 U.S. gal). Note: Do not fill the

tank to the top, since there must be space for expansion in the

tank. Suitable hydraulic oil is Castrol CRML or equivalent

(150 LHM 32 - 68). Typical viscosity rating of 150 - 175 cSt

at 100°c.

Hose diameter should be sizes to ensure that pressure and flow

losses are kept to a minimum. Hoses shall be selected with

appropriate working pressure ratings. The following

connections are provided on your winch.

1. The Valve Block = 3/4” BSPP

2. Pneumatic Freespool = 1/8” BSPP

Pressure and flow loss is increased as hose length increases

and/or bore size decreases. Pressure and return lines in excess

of 3.5 meters should be compensated with an increase in

nominal bore size.

Control Valve4 - way, 3 - position with spring centred, open

centre (ports A & B open when in centre position) and built in

relief valve. The relief valve must be set to the winch

operating pressure. The valve should be mounted as close to

the winch as possible

Load Control Valve: A dual overcentre valve is fitted to the

winch to give smoothly controlled winch out when under load

and to provide full dynamic braking.

Oil Suction Strainer Rating: Approximately 250 microns

Return Line Filter Rating:

10 - 40 microns

INSTALLATION

In all installation work on a hydraulic system, cleanliness and

accuracy are essential so that the hydraulic system functions

properly.

As a general rule:

Bigger Nominal Bore Hose = Better Winch Performance


03 WINCH INSTALLATION

It is important that the winch is mounted securely so that the

motor mount, drum and worm box housing are accurately

aligned.

The tie bars supplied with the winch must remain attached.

It is important that the winch is mounted securely so that the

motor mount, drum and worm box housing are accurately

aligned.

Refer to the mounting diagram, all dimensions are in mm.

The winch, together with its mount plate, if fitted must be

securely bolted to a mounting surface that is flat to within

0.5mm and sufficiently stiff to prevent flexing. A minimum of

8mm, (5/16"), thick steel plate should be used.

Remember that the winch is only as strong as its mounting

system.

All eight mounting holes must be used.

Use the spacers if supplied.

Allthough the winch may be mounted in either the

'overwound' or 'underwound' positions, 'underwound' is

recommended.

Mounting bolts must be 8.8 grade High Tensile Steel or better.

All winch systems must be protected by an efficient

Emergency Stop system, hydraulic winches should be

fitted with a highly visible engine kill system to stop the

vehicle engine driving the hydraulic system.


04MAINTENANCE & USE

WIRE ROPE SPECIFICATION:

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 away from the rope drum (if

supplied as part of your kit), and lock in position through the

corresponding holes in the tensioner frame and bracket using

a suitable pin or bolt.

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 way 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 of the hole and not protruding.

6. Feed back any excess slack to tighten the four wraps

neatly on the drum.

7. Remove the locking pin

from the cable tensioner to

allow the rollers to rest on the

rope. Note: This assembly is

under tension. Special care

should be taken to avoid

trapping fingers, clothing etc.

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.

Two wraps illustrated for clarity.

PULLING OUT THE ROPE

Dis-engage the freespool. With a pair of gloves on, pull out

the rope and secure to anchor or load. Re-engage the

freespool.

PNEUMATIC & HYDRAULIC

1. Disengage the drum by operating the pneumatic control

valve.

2. Pull out the cable by hand, but leave at least 5 wraps on

the drum.

3. Attach the load.

4. Engage the drum by moving the control valve lever to the

appropriate position. The freespool mechanism will spring

return but the drum will not engage until it has been

rotated a little.

DO NOT ATTEMPT to pull a load until the drum is

properly engaged.

NOTE: The mechanism is designed such that it cannot be

disengaged when the drum is under load greater than 50

kg (100 lb).

5. Operate the winch.

MANUAL

1. Disengage the freespool (if engaged) pull the freespool

handle and turn 90 degrees ensuring that the freespool

handle stays OUT.

2. Pull out the cable by hand, but leave at least 5 wraps on

the drum.

3. Attach the load.

4. Engage the freespool by turning the freespool handle 90

degrees and then rotating the drum until the freespool

handle springs IN.

DO NOT ATTEMPT to pull a load until the drum is

properly engaged.

NOTE: The mechanism is designed such that it cannot be

disengaged when the drum is under load greater than 50

kg (100 lb).

5. Operate the winch.

All winch systems must be protected by an efficient

Emergency Stop system, hydraulic winches should be

fitted with a highly visible engine kill system to stop the

vehicle engine driving the hydraulic system.


04 MAINTENANCE & USE

RUNNING IN, MAINTENANCE & SERVICING

For optimum performance all hydraulic motors need running

in. Run for approximately 1 hour at 30% of maximum oil

pressure.

LUBRICATION

Freespool Handle (manual freespool version) lubricate

regularly with light oil.

Planetary Gearbox: The winch is delivered from the factory

filled with the correct type and quantity of oil. Change the oil

in the gearbox at least once a year. The oil specification

recommended is BP ENERGOL GR-XP150 or equivalent,

using approximately 3/4 Litre (0.2 U.S. gal).

ROUTINE SERVICE INSPECTIONS

IMPORTANT - Ensure your winch has been lubricated before

use.

The following inspections should be carried out during

routine vehicle servicing:

1. Check the tightness of mounting bolts and all hydraulic

connections; remove any dirt or corrosion that may have

accumulated. Check the winch for operation in both

directions.

2. Repairs should be carried out by authorised Superwinch

repair centres only. Do not attempt disassembly of the

gearbox. Disassembly will void warranty.

SERVICING

Before you contact Superwinch or your nearest Dealer for

parts, please have ready the following information:

* Kit No. * Serial No. of Winch * Part No. Required

When ordering spare parts from these lists, always quote the

winch serial number and the part number not item number of

the spare part required. This will ensure the correct part is

despatched to you. The serial number of your winch is located

on the data plate on the motor support casting.

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 rope drum. 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 practise is to rewind the rope

under tension after each use.

3. Prevent kinks before they occur.

a) This is a 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.

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 gears 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.


05SPARES & ACCESSORIES

Item Description Part Number Qty.

1 Freespool Assembly. 70-90008 1

2 Clutch Housing. 70-25049 1

3 Face Seal. 4-22-180204143 2

4 Flange Bearing. 10049 1

5 Spherical Plain Bearing. 4-99-04006228 1

6 Sliding Dog. 70-50034 1

7 Circlip. 4-24-4556183 1

8 Spacer. 70-50081 1

9 Skt Hd Set Screw, M8 X 12. 4-40-081203 1

10 Rope Drum Assembly. 70-90006 1

11 Driveshaft. 70-50032 1

12 Plain Bearing. 4-62-4550303 2

(Must be ordered with Drum)

13 Drum Spacer. 70-60012 1

14 Relief Valve. 70-90561 1

15 Oil Seal. 4-22-4560083 1

16 Brake Shoe. 317 2

17 Brake Spring. 320 2

18 Wormbox. 70-25009 1

19 Ball Bearing. 4-13-040090233 2

20 Thrust Washer 4-03-4060103 2

21 Key. 557 2


22 WormWheel / Worm Set. 70-95020 1

23 Gasket. 70-60011 1

24 Wormbox Cover. 70-25010 1

25 Hex Set Screw, M8 X 25. 4-32-0802522 8

26 Spring Washer, M8. 4-51-0823 8

29 Tie Bar. 70-52146 2

30 Hex Hd SetScrew, M10 X 25. 4-32-1002522 8

31 Spring Washer, M10 4-51-1023 8

32 Needle Roller Bearing. 4-12-30372013 2

33 Thrust Washer. 4-09-3052163 2

34 Worm / Wormwheel Set. 70-95020 1

35 Key. 128 1

36 Oil Seal. 4-22-3042073 1

37 Gasket 70-60010 1

38 'O' Ring. 4-21-05963 1

39 Cap Hd Screw, M8 X 25. 4-36-0802522 4

40 Spring Washer, M8. 4-51-0823 4

41 Drive Adaptor. 70-90545 1

42 Drive Coupling. 70-90009 1

43 Hydraulic Motor. 94-32192-01 1

44 Cap Hd Screw, M12 X 40. 4-36-1204022 2

45 Spring Washer, M12. 4-51-1223 2


05 SPARES & ACCESSORIES


Complete Manual F/S Assembly 54-90218 (1)

1 Button Hd Screw 4-38-081023 1

2 Head, Release 54-50245 1

3 Body, Release 54-50246 1

4 Selector Shaft 54-50244 1

5 Spring 4-31-50763223 1

6 Freespool Fork 70-25012 1

7 Freespool Housing 54-25044 1

8 Gasket 54-60066 1

9 Gearbox Cover 54-25161 1

10 Clutch Member 54-50243 1

11 Drive Input Gear 54-50020 1

12 Set Screw, M8 X 25 4-32-0802522 7

13 Spring Washer, M8 4-51-0823 7

14 Drive Shaft Plug 54-50256 1

15 Plug, Filler / Level 4-29-224 3

16 Input Drive Shaft 54-50261 1

17 Sun Gear 54-50019 1


Complete Pneumatic F/S Assembly 54-90647 (1)

1 Freespool Housing 54-25045 1

2 'O' Ring 4-21-2053 1

3 Spring 4-31-50764823 1

4 Washer 4-02-4050253 1

5 Cylinder Assembly 54-95058 1

6 Gasket 54-60066 1

7 Pneumatic connector 54-50354 1

8 Piston Assembly 54-95058 1

9 Gearbox Cover 54-25161 1

10 Drive Input Gear 54-50020 1

11 Sun Gear 54-50019 1

12 Input Drive Shaft 54-50261 1

13 Setscrew, M8 X 25 4-32-0802522 7

14 Spring Washer, M8 4-51-0823 7

15 Drive Shaft Plug 54-50256 1

16 Freespool Seal set 54-95057 1

17 Plug, Filler / Level 4-29-224 3

18 'O' Ring 4-21-1953 1

PNEUMATIC FREESPOOL

MANUAL FREESPOOL


05 Optional accessories, designed by Superwinch exclusively for the H20P / H25P / H30P:

Rope Drum Safety Guard

Part No. 54-30178

Roller Fairlead

Part No. 254001

Cable Tensioner

Part No. 5683

Wire Ropes

Part No. 201645, 16mm x 45m

Part No. 201845, 18mm x 45m

Part No. 202045, 20mm x 45m

Part No. 0573, 20mm x 50m

OPTIONAL ACCESSORIES

SUPERWINCH LIMITED WARRANTY VALID WORLD WIDE

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 inlieu 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. Repair 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 Owner’s 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. Incidential and Consequential Damages. Subject to seller’s Limited Warranty obligations set forth herein, seller shall

not be responsible for incidential damages of any kind, or the consequential damages to property, loss of profits 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 limitation or exclusion

may not apply to you.

D. Condition of 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 includem but it not limited to, installation or use of the Superwinch wihtout

compliance with the instructions contained in the Superwinch Owner’s Manual for the particular model number. Seller’s 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 liatbility 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 specific legal rights, and you may also have other right 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 district court in the USA or to appropriate jurisdictions outside the USA.

Inquiries. Any enquires regarding compliance with the warranties provided herein may be addressed in writing to:


06

Superwinch LTD.

Union Mine Road, Pitts Cleave

Tavistock, Devon. PL19 0NS

Tel: +44 (0) 1822 614101

Fax: +44 (0) 1822 615204


Superwinch LLC.

Winch Drive, Putnam

Connecticut 06260 U.S.A.

Tel: 01 800 323 2031

Fax: 01 860 963 0811


5-201-007 iss 1 - h30 pro manual 5-201-007 issue 1...owners manual 5-201-007 issue 1 page 6 03 winch...

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