HES OzWinch Signature II Series User manual

HWA3500 Series
HWA5000 Series
Revision: 2.0

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AC Electric Winch
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Proprietary Statement
© Copyright 2020 HES Winches Australia. All rights reserved. No part of this
publication may be reproduced, photocopied, stored on a retrieval system, or
transmitted without the express prior written consent of the publisher.
Disclaimer
While all care has been taken in the development of this product, no loss of any
kind is accepted by HES Winches Australia or its agents arising from the use of
this document.
HES Winches Australia makes no representations or warranties with respect to
the contents of this document, and specifically disclaims any express or implied
warranties or fitness for any particular purpose. Further, HES Winches Australia
reserves the right to revise this publication and to make changes to its contents,
at any time, without obligation to notify any person or entity of such revisions or
changes.
Trademarks
HES Winches Australia is a registered trademark. Other trademarks may exist
which are not explicitly noted here and they remain registered to the
appropriate organisations.
Revision History
Revision
Date
Details of Change
1.0
22/06/2015
First Release
1.1
30/04/2018
QR Code & Contact update
2.0
18/09/2020
Second Release

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Table of Contents
Preface
CHAPTER 1 | Safety
Safety Overview ...................................................................................................................7
Task Safety Process ..............................................................................................................7
Winch Preparation ..............................................................................................................9
Post-Delivery Inspection .....................................................................................................9
General Checks before Use ..............................................................................................9
Safe Operation ....................................................................................................................9
Operating Safety Rules.......................................................................................................9
Before Commencing Work: ...............................................................................................9
Overheating.......................................................................................................................11
Maintenance Safety .........................................................................................................11
General Safety Rules.........................................................................................................11
CHAPTER 2 | System Overview
General Description...........................................................................................................12
Specifications .....................................................................................................................12
Options ................................................................................................................................13
Angle Chart ........................................................................................................................14
General Assembly..............................................................................................................15
CHAPTER 3 | Installation
Mounting Dimensions ........................................................................................................18
CHAPTER 4 | Operation
Operator Controls ..............................................................................................................19
Emergency Stop.................................................................................................................20
Pre Start-up .........................................................................................................................20
Start-up & Operation .........................................................................................................20
Shutdown ............................................................................................................................21
Routine Running Checks ...................................................................................................21
Maintenance......................................................................................................................21
Appendix 1 | Warranty Terms and Conditions

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Contact Details
Head Office
Phone: [phone]
Mobile: [phone]
Email Sales: [e-mail]
Email Accounts: [e-mail]
Website: www.heswinches.com.au
Postal: HES Winches Australia
P.O. Box 688
Helensvale
Queensland 4212
Australia
Address: 27/ 11-17 Cairns Street
Loganholme
Queensland 4129
Australia

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Preface
We thank you for choosing a HES Winches Australia product. This document provides
the information necessary to safely operate and maintain the winch.
This equipment is the result of extensive design and development and is
acknowledged as being a superior product in its category. We congratulate you on
your discerning choice and wish you many years of productive service.
Read this manual carefully before operating the equipment or performing any
maintenance on the winch. It is advised that this manual be kept with the machine at
all times as a reference.
For further information please contact HES Winches Australia using the contact details
provided on the previous page.
Warranty
As Australia’s leading winch supplier, we understand that in addition to getting the
best equipment for your requirements, you also need to keep it operational, which is
why we back our superior equipment with responsive service and repair capabilities.
All repairs and maintenance are performed by accredited technicians.
An extensive selection of spare parts for most models is available to minimise any
delays to equipment repairs.
HES Winches Australia provides a limited warranty for goods of our own manufacture
against defective workmanship and materials which have substantially diminished or
are likely to substantially diminish the life or functionality of the goods for a period of
twelve months from the date of despatch.
To read the full warranty terms and conditions please refer to Appendix 1 located at
the rear of this manual.
For any warranty claims please contact HES Winches Australia.
HES Winches Australia reserves the right to request any claimant to supply a copy of
the original tax invoice as part of the claim.

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AC Electric Winch
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CHAPTER 1 | Safety
There are safety risks for people and machinery when working with this
winch system. Compliance with safety precautions and risk management
standards are vital in mitigating the risk of injury, or damage to the
equipment.
Following the safety guidelines will help minimize the risk of injury and ensure a trouble
free working life for your winch.
Safety Overview
Read and follow all operating and safety instructions contained in this Owner’s
Manual.
If you are unable to identify hazards or do not understand the process for use of the
RISK MATRIX, stop the job and consult a qualified Occupational Health and Safety
consultant.
WARNING
This symbol has been used throughout this manual and on the
equipment to highlight important safety information. Ensure you
read and understand the information before embarking on any
related task.
Task Safety Process
Always evaluate the risk factors before starting any work that involves winches.
Plan Your Task
List the activities required to undertake the task. Use the Task Planning
Ensure that the safety processes are understood and communicated to all
persons involved with the task.
Identify the Risks
Why, when, how what can risk occur?
Assess the Risks
Determine the likelihood of a hazard occurring.
Determine the severity of the consequence.
Determine the "Action Required" to prevent the hazard from occurring.
Implement Controls
Consider how risks can be mitigated by implementing controls such as:
oSafe work practices and procedures
oUsing appropriate equipment or specific people that have
experience.
oEstablishing barriers, or setting up safety mechanisms such as guards.
oWearing the correct PPE for the task.

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Are the Risks acceptable?
If NO – formulate controls to mitigate the risk and re-assess the task.
If YES – Organise the task, maintain controls, communicate instructions
clearly, monitor and review progress.
Monitor and Review
Work methodically, check on progress, and communicate.
Continually monitor the situation by reaffirming:
oIs the plan being followed?
oAre controls adequate?
oIs further assessment required?
oHave conditions changed?
If yes, then stop the task and review the plan.
Figure 1. Task planning chart

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Winch Preparation
Following delivery of the winch, some basic checks should be conducted to ensure
the system can be prepared for safe operation.
Post-Delivery Inspection
The winch needs to be inspected for any evidence of damage that may have
resulted during transport or shipment before it is declared ready for use.
Note: If the Owner’s Manual for the winch has not been received, immediately
contact HES Winches Australia to obtain a copy. Do not inspect, operate or perform
maintenance on the winch without having Owner’s Manual.
General Checks before Use
Winch:
•Visually inspect the winch and all components for any visible damage.
•Inspect all operator controls and ensure they are functional (i.e. levers move
as intended, are not bent or missing).
•Inspect all areas for evidence of fluid leaks.
Safe Operation
In order to ensure the safety of operators and others, it is important that the machine
is used appropriately, that design limits are not exceeded and that all risks have been
identified and the appropriate risk control measures implemented.
Operating Safety Rules
To ensure the safe winch operation, the following basic Safety Rules must be
understood and complied with at all times.
Before Commencing Work:
Action the Daily Operator Checklist.
Table 1. Daily Operator Checklist
DAILY CHECKS
Safety
Guarding
Ensure that all safety guards or panels are in good
condition and securely fastened.
Operator
Controls
Ensure that the operational controls are all functioning as
expected
Structure
Ensure that the winch frame and chassis is free from
damage such as cracks or corrosion.
Bolts and
Fasteners
Ensure that all fasteners (especially those for mounting
the machine) are tight, that none are missing or
damaged.
Fluids
Ensure that there are no fluid leaks and that all required
lubrication has been carried out.

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Ensure all safety instructions are clearly understood and that the operators
are familiar with the winch controls.
Review the working site for hazards and implement the risk control
measures.
Ensure there are no unused ropes, cables, or obstructions around the
working area.
Be aware of vessel/vehicle movement.
Ensure persons are correctly positioned and know what their involvement
and tasks are in relation to the job at hand.
Ensure that ropes or cables to be used are correctly rated for the task, are
not damaged or worn and where appropriate have the necessary
test/examination certificates up to date.
During operations:
Always wear approved, appropriate Personal Protective Equipment (PPE).
Pay attention. Keep alert, and avoid being distracted whilst operating the
winch. Don’t stand under a load, or in areas where overhead equipment
may swing and cause serious injury.
Keep body parts and clothing away from all moving parts as well as the
rope.
Never exceed the maximum load specified for the winch.
Avoid sudden shock or movement of the winch under load and use a slow
consistent speed.
Turn off power and remove power lead from electrical supply whenever
the winch is to be left unattended.
Secure any loose items, tools or equipment so that these will not become
an operational hazard.
Be aware of non-operating persons in proximity to the equipment, as well
as the winch cable or rope.
Always ensure clear communication between the machine operator and
other persons involved with the task.
WARNING:
Do not place feet or hands in proximity of rotating parts.
Do not smoke (or approach the winch with a naked flame) whilst
operating or refuelling.
Do not leave the motor running whilst refuelling.
Do not guide cable with hands or feet.
Do not tie or secure yourself to any part of the winch or equipment.
Do not touch fittings, friction parts or guards whilst operating.
Do not remove safety decals.
Do not remove safety guarding.

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Overheating
The Power Pack is a fully enclosed unit and under extreme conditions may overheat.
If the unit is continuously operated under full load for a long period of time, the
temperature may rise to an excessive level. Turn off the unit and let it cool down prior
to restarting.
CAUTION
The winch must always be switched off and unplugged from the power
source when the winch is unattended or not in use for an extended period
of time.
Maintenance Safety
The HWA3500SS and HWA5000SS series electric winch is virtually maintenance free.
In the event the winch requires repair contact HES Winches Australia for further
information.
The following sections provide guidelines on how to ensure safety whilst externally
servicing the winch equipment.
General Safety Rules
Prior to conducting any work on the structure, the power pack or mechanical
components of the winch:
Ensure the machine has been powered down or isolated
Wear the appropriate PPE
Ensure that all loads under tension have been lowered and secured
Ensure that the correct tools for the work are available
Keep an extinguisher at hand in case of fire
WARNING
Do Not remove the covers of this winch system. All repairs must be
performed by a qualified person only.
Contact HES Winches Australia for further information.

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CHAPTER 2 | System Overview
General Description
Proudly Australian-made, OzWinch Signature Series II electric winch is a compact and
robust winch which has been designed for a variety of hauling applications and is
ideally suited as a slipway or boat ramp winch.
Driven by a worm gear transmission providing a quiet, safe, maintenance free
operation and coupled to a purpose built powerful electric brake motor, available in
both 240V and 415V options.
With the frame, guards, motor cover and bearings fabricated in marine grade 316
stainless steel, the OzWinch Signature Series II electric winch offers superior outdoor
protection and longevity.
Specifications
Characteristics
Description
GEARBOX
Worm Drive Gear Ratio 140:1
ELECTRIC BRAKE MOTOR
1.1kW Single Phase 240v (HWA3500SS.1)
1.1kW Three Phase 415v (HWA3500SS.3)
1.7kW Single Phase 240v (HWA5000SS.1)
1.5kW Three Phase 415v (HWA5000SS.3)
LOW VOLTAGE PENDANT CONTROL
24V AC with 10M cord with Emergency
Stop Button
POWER – 240V MODELS
Wired Power Lead and 3 Pin Plug
POWER – 415V MODELS
Isolator Switch Termination
CABLE - STANDARD
35m x 8mm dia. G2070 Aircraft Grade
7x19 Galvanised Rope
MAX WINCH DRUM STORAGE CAPACITY
70m of 8mm Diameter Rope
MAX LINE PULL – FIRST LAYER
1000kg at 4.0m/min
AVERAGE LINE SPEED
5.0m/min
WEIGHT (APPROX)
HWA3500SS Series
94kg
HWA5000SS Series
100kg

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Options
Product
Part Number
Description
OW-SS-REMOTE
Wireless remote control
OW-SS-TENSIONER
Rope tensioner kit to suit all HWA3500SS and
HWA5000SS Series winches
SR/MISC
Dyneema SK75 Synthetic Rope replacement
option
OW-SS-PEDESTAL
Pedestal Stand to suit all HWA3500SS and
HWA5000SS Series winches

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Angle Chart
The maximum weight the OzWinch Signature Series II electric winch can haul
depends on the angle of the hauling surface e.g. driveway or slipway.
To determine the safe weight for the angle of the hauling surface, calculate the total
weight of the hauling object (e.g. boat and trailer or other vehicle). Use the angle
chart below in Table 2 to assess the maximum weight to safely haul the object
against the angle of the hauling surface.
Table 2. Angle Chart
ANGLE OF HAULING SURFACE IN DEGREES (GRADIENT)
WINCH
MODEL
5°
(1:12)
10°
(1:6)
12.5°
(1:4.5)
15°
(1:3.75)
20°
(1:2.75)
25°
(1:2.1)
30°
(1:7.3)
HWA3500SS 7600kg 4300kg 3500kg 3000kg 2400kg 1900kg 1600kg
HWA5000SS 10600kg 6020kg 5000kg 4200kg 3360kg 2660kg 2240kg
All figures given in the Angle Chart are based on a hard surface such as concrete or
steel tracks with bearing steel wheels or rubber tyres.
The total hauling object maximum weight determines the limit of the angle of the
ramp.
CAUTION
Never exceed the safe maximum weight and angle when operating the
electric winch.

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General Assembly
Figure 2. General assembly parts identification diagram.
Reference: HES1204-001

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Figure 3. General assembly exploded view parts identification diagram.

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Table 3. General Assembly Parts Listing
ASSEMBLY REF: HES1204-001
No.
Qty.
Description
Part Number
1
1
WINCH DRUM SHAFT
HES1204-102
2
1
10x8x50 LONG KEY
BS 4235-1
3
1
10x8x49 LONG KEY
BS 4235-1
4
2
WINCH CHEEK PLATE
HES1204-103
5
1
WINCH GEARBOX SIDE PLATE
HES1204-100-SS
6
1
MOTOVARIO - GEARBOX
NMRV-P090-HW40 110/1 D90B5
7
1
ELECTRIC MOTOR
CONTACT: HES WINCHES
8
1
WINCH GEARBOX RETAINING PLATE
HES1204-104
9
3
WINCH FRAME TIE BAR
HES1204-105
10
1
WINCH FRAME TIE BAR
HES1204-105-SS
11
1
ROPE TENSIONER ARM
HES1204-110
12
1
ROPE TENSIONER PIVOT BAR
HES1204-111
13
2
ROPE TENSIONER SPRING MOUNT
HES1204-112
14
2
EXTENSION SPRING
HES1204-ES13
15
1
WINCH BEARING SIDE PLATE
HES1204-101-SS
16
1
FLANGED BEARING HOUSING
F210FAG
17
1
SHAFT BEARING
SUC210ECO
18
1
WINCH DRUM COVER PLATE
HES1204-106-SS
19A
1
GEARBOX / MOTOR COVER
(HWA3500SS Series only)
HES1204-204-SS
19B
1
GEARBOX / MOTOR COVER
(HWA5000SS Series only)
HES1204-212-S
20
1
GEARBOX GASKET
HES1204-207
21
1
GEARBOX / MOTOR COVER GASKET
HES1204-208
22
1
GEARBOX / MOTOR COVER GASKET
HES1204-209
23
1
TERMINAL BOX
HES1204-115
100
1
M16x45 HEX HD BOLT C/W FLAT
WASHER
ASTM A193 - SS 316
101
12
SET SCREW HEX HD M16x25 C/W FLAT,
SPRING WASHER
ASTM A193 - SS 316
102
4
SET SCREW HEX HD M14x40 C/W NUT,
SPRING WASHER
ASTM A193 - SS 316
103
6
SOCKET HEAD CAP SCREW M12x25
C/W SPRING WASHER
ASTM A193 - SS 316
104
4
SET SCREW HEX HEAD M10x25 C/W
FLAT WASHER
ASTM A193 - SS 316
105
3
M10x16 HEX HD BOLT C/W SPRING
WASHER
AS1111 - 4.6
106
8
M6x20 HEX HD BOLT C/W FLAT WASHER
ASTM A193 - SS 316
107
1
SOCKET SET SCREW CUP POINT M6x8
ASTM A193 -SS 316
108
4
M10x40 HEX HD BOLT C/W NUT, FLAT,
SPRING WASHER
AS1111 - 4.6 (23 GRIP)

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CHAPTER 3 | Installation
The winch is mounted to the hauling surface via the 4 x 21mm holes, the winch can
be mounted to a variety of substrates and the mounting hardware should be
matched accordingly.
Mounting Dimensions
The winch can be mounted through the four (4) mounting holes to the client
engineered mounting foundation. The mounting holes located at each corner of the
winch chassis.
Figure 4. Winch mounting dimensions.

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CHAPTER 4 | Operation
To ensure the safe operation of your OzWinch Signature II Series winch refer to Task
Safety Process on page 7 for further details and how to assess risk. All safety rules,
decals and instructions must be understood and complied with at all times.
CAUTION
Consult with a qualified electrician prior to using the winch with an
extension lead.
Operator Controls
The HWA3500 and HWA5000 Series electric winch is suited to home and commercial
boat ramp and other hauling applications, and it can be used single line pull or
double reeved.
For single line pull applications refer to Table 2. Angle Chart to determine the safe
weight of the hauling object that can be hauled depending on the angle of the
hauling surface.
The pendant controller is plugged in to the matching plug on the winch control box,
the pendant is low voltage (24V AC) with a 10m lead.
Figure 5. Pendant Controller
Radio Control
The winch has an optional radio control, the radio control is 433 MHz and works in
conjunction with the pendant control. Operation is push button up / down, when
holding the button in the winch operates, when released the winch stops and the
automatic failsafe brake engages. There is an emergency stop on the winch control
box.
Figure 6. Optional Radio Control

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Emergency Stop
There are two "EMERGENCY STOP" switches to isolate and stop
operation of the winch.
1. Located on the top of the Terminal Box.
2. The pendant controller
The Estop is a good safety feature once the boat is in position to prevent inadvertent
operation.
Use the Emergency Stop button in case of fire or any other danger which poses an
immediate risk to personnel or machinery. To activate the stop, press the
"EMERGENCY STOP" button all the way in until the button clicks into the down position.
To re-set the emergency stop for winch control can continue, release the
"EMERGENCY STOP" button from the down position, twist the button clockwise.
CAUTION
The winch must always be switched off and unplugged from the power
source when the winch is unattended or not in use for an extended period
of time.
Pre Start-up
1) Before starting the system or commencing operation, refer to the General
Checks before Use the on page 9.
2) Complete a daily operator checklist prior to use for each winch, refer to the
Table 1. Daily Operator Checklist on page 9 for further information.
CAUTION
Never start the power unit when a LOCK-OUT tag is present.
Start-up & Operation
1. Plug in the winch and pendant.
2. Operation is push button up / down.
oHold the button in to operate the winch.
oRelease the button to stop the winch, the automatic failsafe brake will
engage.
3. Use the emergency stop on the pendant control as a safety measure once
the boat is in position to prevent inadvertent operation.
CAUTION
Connection to your boat trailer should be matched to the weight being
hauled, as a minimum use a 1T D shackle.