DEMA Manual Winch 3.2t (Model 910002-68018) Instruction Manual

1. Introduction

This manual provides essential information for the safe and proper use of your DEMA Manual Winch 3.2t, Model 910002-68018. This robust hand winch is designed for pulling, lashing, holding, tensioning, and securing loads up to a maximum weight of 3200 kg. It features a durable aluminum housing, a 20-meter special steel wire rope, and a telescopic lifting bar. Please read this manual thoroughly before initial operation to ensure safety and optimal performance.

Figure 1: The DEMA Manual Winch 3.2t, including the winch unit, 20-meter steel wire rope with safety hook, and telescopic operating handle.

2. Safety Instructions

Adherence to these safety instructions is crucial for preventing accidents and ensuring the longevity of the device. Always prioritize safety during operation.

• Changes made by the manufacturer for technical progress may occur without prior notice and might not be reflected in this manual.
• Before commissioning, inspect the device for completeness and proper function. Never operate a defective or non-functional device. Contact the manufacturer or have the device inspected by a qualified mechanic.
• Always work with caution and the necessary care.
• Never apply excessive force to the winch or its components.
• Before each use, check all screws on the manual winch and tighten them if necessary.
• Always wear appropriate personal protective equipment (PPE) when working with the winch, including protective gloves, safety shoes, work clothing, a safety helmet, and safety glasses.
• Ensure the operating levers move smoothly and are not obstructed.
• After each use, inspect the wire rope for any damage or breaks. Replace damaged ropes immediately with an equivalent type.
• Never pull both operating levers simultaneously.
• Do not press the locking lever downwards when the rope is under tension.
• Avoid applying excessive force to the levers, as this can damage the winch.
• Use only adequate and approved spare parts.
• Only use the supplied extension rod. Using other extension rods will void the warranty.
• Never work under or on lifted loads.
• Keep children and unauthorized persons away from the winch during operation.
• If the load begins to move unintentionally, stop the operation immediately.
• If the wire rope is damaged, replace it only with an equivalent wire rope.
• Never insert the rope from the anchor bolt side, as this will prevent proper clamping and compromise winch function.
• Keep the winch clean and prevent contaminants such as dirt, stones, or similar from entering the mechanism.
• Do not operate the winch if you are tired or under the influence of alcohol, drugs, medication, or other intoxicating substances.
• Store packaging materials (foils, plastic bags, styrofoam, etc.) out of reach of children, especially infants, as they may pose choking hazards.

2.1 Intended Use

• The manual winch is designed for pulling and lifting loads up to a maximum weight of 3.2 tons.
• The manual winch is not suitable for pulling or lifting people.

2.2 Pictogram Explanation

• Read the operating manual before first use!
• Do not step under lifted loads!

Figure 2: Original safety instructions and pictogram explanations from the manufacturer's manual.

3. Product Components

The DEMA Manual Winch 3.2t consists of the following main components:

• Winch Unit: Robust aluminum housing containing the internal pulling mechanism.
• Steel Wire Rope: A 20-meter long, 16mm diameter special steel wire rope with a safety hook.
• Telescopic Operating Handle: Used to operate the forward and reverse levers.
• Shear Bolts: Two safety bolts designed to protect against overload.

Figure 3: The 20-meter steel wire rope, coiled, with its attached safety hook.

Figure 4: Detailed view of the robust safety hook, designed to securely attach to loads.

Figure 5: The telescopic operating handle, shown disassembled into its two main sections.

Figure 6: The telescopic operating handle fully extended, ready for use.

Figure 7: The two brass shear bolts, which act as overload protection for the winch.

4. Setup

Before operating the winch, ensure it is properly set up and the rope is correctly inserted.

4.1 Inserting the Rope

1. Press the locking lever (labeled 'Fixierhebel' in Figure 8) downwards and push it towards the reverse lever (labeled 'Rückwärtshebel' in Figure 8) until the locking lever engages.
2. Slide the steel wire rope into the designated opening (labeled 'Öffnung' in Figure 8) and feed it through the entire winch mechanism.
3. Once the wire rope has passed through the winch, pull it through as far as necessary for your application.
4. Press the locking lever downwards again and pull it forward to securely clamp the rope within the winch.
5. The manual winch is now ready for operation.

Important: Never insert the rope from the anchor bolt side, as this will prevent it from being properly clamped and the winch will not function correctly (refer to Figure 9).

Figure 8: Illustration of inserting a shear bolt into the winch's handle socket. This bolt is designed to break if the winch is overloaded, protecting the mechanism.

Figure 9: Diagram illustrating the correct method for inserting the rope into the winch, highlighting the forward and reverse levers and the locking mechanism. The image also shows an incorrect rope insertion method.

5. Operating Instructions

Once the rope is correctly inserted and clamped, the winch is ready for use.

• To pull in the rope and move the load, operate the forward lever (labeled 'Vorwärtshebel' in Figure 9) using the telescopic handle.
• To release the rope and move the load in the opposite direction, operate the reverse lever (labeled 'Rückwärtshebel' in Figure 9) using the telescopic handle.
• Always apply steady and controlled force to the levers. Avoid sudden jerks.
• Monitor the load and the winch mechanism continuously during operation.
• If the winch encounters resistance or the shear bolt breaks, stop operation immediately.

6. Maintenance

Regular maintenance ensures the longevity and safe operation of your DEMA Manual Winch.

• Cleaning: Keep the winch unit clean and free from dirt, mud, stones, and other debris. A clean winch operates more efficiently and reduces wear.
• Lubrication: Periodically lubricate moving parts as recommended by the manufacturer (refer to specific product documentation if available).
• Rope Inspection: Regularly inspect the steel wire rope for fraying, kinks, broken strands, corrosion, or other damage. Replace the rope immediately if any damage is found.
• Shear Bolts: Always have spare shear bolts on hand. These are designed to break under overload to protect the winch mechanism. Replace a broken shear bolt only with an original or equivalent part.
• Storage: Store the winch in a dry, clean environment when not in use to prevent corrosion and damage.

7. Troubleshooting

This section addresses common issues you might encounter with your manual winch.

• Winch not pulling/releasing:
  • Check if the rope is correctly inserted and clamped. Refer to Section 4.1.
  • Ensure the locking lever is fully engaged or disengaged as required for the operation.
  • Inspect the levers for smooth movement. Lubricate if stiff.
• Winch feels jammed or overloaded:
  • Stop operation immediately.
  • Check if a shear bolt has broken. If so, replace it with a new one.
  • Verify that the load does not exceed the winch's 3.2t capacity.
  • Ensure the rope is not snagged or obstructed.
• Rope damage:
  • If the rope shows any signs of damage (fraying, kinks, broken strands), replace it immediately with an equivalent 16mm, 20m steel wire rope. Do not attempt to repair a damaged rope.
• Difficulty disengaging jaws (as per user feedback):
  • If the jaws are difficult to disengage, try placing the winch upright, securing it, and gently tapping the smaller, third lever with the palm of your hand to release the mechanism. This can help if the internal components are stiff or slightly misaligned.

8. Specifications

9. Warranty and Support

Information regarding specific warranty terms and conditions for the DEMA Manual Winch 3.2t is not provided in this document. For warranty claims, technical support, or to inquire about spare parts, please contact your retailer or the manufacturer directly. Ensure you have your purchase receipt and model number (910002-68018) available when contacting support.

Using only the supplied extension rod is critical, as the use of other extension rods will result in the loss of warranty.