Husar Winch BST H 12000 Lbs Quick reference guide

Assembly & Operating Instructions
HYDRAULIC WINCHES
BST H 12000 Lbs
BST H 15000 Lbs
BST H 18000 Lbs
BST H 20000 Lbs
BST HS 12000 Lbs
BST HS 080 Lbs
BST H 35000 Lbs
BST 45000 Lbs

CONTENTS
INTRODUCTION.....................................................................................1
SAFETY WARNINGS AND PRECAUTIONS..........................................2
WINCH WARNINGS AND PRECAUTIONS............................................3
UNPACKING...........................................................................................4
INSTALLATION......................................................................................4
OPERATION...........................................................................................8
WINCH ACCESSORIES YOU WILL NEED ..........................................10
RIGGING TECHNIQUES ......................................................................10
LUBRICATION...................................................................................... 11
CABLE ASSEMBLY REPLACEMENT .................................................11
TROUBLE SHOOTING......................................................................... 12
WINCH ASSEMBLY DRAWING(BST)..................................................13
WINCH PARTS LIST(BST)...................................................................14
WINCH ASSEMBLY DRAWING(BST HS12000lb)...............................16
WINCH PARTS LIST(BST HS12000lb)................................................17
WINCH ASSEMBLY DRAWING(BST HS080 lb)..................................18
WINCH PARTS LIST(BST HS080 lb)...................................................19
SPECIFICATION（BST H12000 lb）...................................................20
SPECIFICATION（BST N15000 lb）...................................................21
SPECIFICATION（BST N18000 lb）...................................................22
SPECIFICATION（BST HS12000 lb）.................................................23
SPECIFICATION（BST HS080 lb）.....................................................24
SPECIFICATION（BST H35000 lb）...................................................25
SPECIFICATION（BST H45000 lb）...................................................26

1
INTRODUCTION
Congratulations on your purchase of a high quality winch. We design and
build winches to strict specifications and with proper use and
maintenance should bring you years of satisfying service.
WARNING - Read, study and follow all instructions before
operating this device. Failure to heed these instructions may result
in personal injury and/or property damage.
Your winch can develop tremendous pulling forces and if used unsafely or
improperly could result in property damage, serious injury or death.
Throughout this manual you will find the following symbols for caution,
warning and danger. Pay particular attention to the notes preceded by
these symbols as they are written for your safety. Ultimately, safe
operation of this device rests with you, the operator.
This indicates a potentially hazardous situation, which if not avoided, may
result in minor or moderate injury. This notation is also used to alert you
against unsafe practices.
This indicates a potentially hazardous situation, which if not avoided, could
result in death or serious injury.
CAUTION
WARNING

2
SAFETY WARNINGS AND PRECAUTIONS
WARNING: When using the tool, basic safety precautions should always be
followed to reduce the risk of personal injury and damage to the equipment. Read all
this instructions before using this tool!
WARNING –Keep children away. Children must never be allowed in the work
area Do not let them handle machines, tools, or extension cords.
WARNING –Store idle equipment. When not in use, tools must be stored in a
dry location to inhibit rust. Always lock up tools and keep out of reach of children.
WARNING –Dress properly. Do not wear loose clothing or jewelry as they can
be caught in moving parts. Protective, electrically non-conductive clothes and non-skid
footwear are recommended when working. Wear restrictive hair covering to contain
long hair.
WARNING –Use eye and ear protection. Always wear impact safety goggles.
Wear a full face shield if you are producing metal filings or wood chips. Wear a dust
mask or respirator when working around metal, wood, and chemical dusts and mists.
WARNING –Maintain tools with care. Keep tools sharp and clean for better and
safer performance. Follow instructions for lubricating and changing accessories.
Inspect tool cords periodically and, if damaged, have them repaired by an authorized
technician. The handles must be kept clean, dry, and free from oil and grease at all
times.
WARNING –Disconnect switch. Unplug switch when not in use.
WARNING –Stay alert. Watch what you are doing, use common sense. Do not
operate any tool when you are tired.
WARNING –Check for damaged parts. Before using any tool, any part that
appears damaged should be carefully checked to determine that it will operate
properly and perform its intended function. Check for alignment and binding of moving
parts; any broken parts or mounting fixtures; and any other condition that may affect
proper operation. Any part that is damaged should be properly repaired or replaced by

3
a qualified technician. Do not use the tool if any switch does not turn “On”and “Off”
properly.
WARNING –Replacement parts and accessories. When servicing, use only
identical replacement parts. Use of any other parts will void the warranty. Only use
accessories intended for use this tool.
WARNING –Do not operate tool if under the influence of alcohol or drugs.
Read warning labels on prescription to determine if your judgment or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.
WINCH WARNINGS AND PRECAUTIONS
WARNING –Keeps hands and body away from Fairlead (cable intake slot) when
operating.
WARNING –Secure vehicle in position before using winch.
WARNING –Be certain winch is properly bolted to a structure (or vehicle) that can
hold the winch load.
WARNING –Do not use inappropriate attachments to extend the length of the
winch cable.
WARNING –Never lift people or hoist loads over people.
WARNING –Never come in between the winch and the load when operating.
WARNING –Do not apply load to winch when cable is fully extended. Keep at
least 5 full turns of cable on the reel.
WARNING –After moving an item with the winch, secure the item. Do not rely on
the winch to hold it for an extended period.
WARNING –Examine winch before using. Components may be affected by
exposure to chemicals, salts, and rust.
WARNING –Never fully extend cable while under load. Keep 5 complete turns of
cable around the winch drum.
WARNING –Never operate winch if cable shows any signs of weakening, knotted
or kinked.

4
WARNING –Winch does not have a locking mechanism. Secure load after
moving.
WARNING –Do not cross over or under cable under load.
WARNING –Do not move vehicle with cable extended and attached to load to pull
it. The cable could snap.
WARNING –Use gloves while handling cable.
WARNING –Apply blocks to vehicle when parked on an incline.
WARNING –Re-spool cable properly.
WARNING –Winch cable must be wound onto the drum under a load of at least
10% rated line pull or outer wraps will draw into inner wraps and damage winch cable
WARNING –Whenever before your winch start to working, please slightly test-run
your winch in two direction each last one or two second, even if the winch drum only
round a few degree of angle, ensure the winch is well-balanced, especially after you
operated the clutch, test-running winch can make winch in gear.
UNPACKING
When unpacking, check to make sure all parts is included. Refer to Assembly
Drawings and Parts List (both with like item numbers) at the end of this manual.
INSTALLATION
1. Your winch is designed with a bolt pattern that is standard in this class of winch.
Many winch mounting kits are available that utilize this bolt pattern for the most
popular vehicle and mounting channels. If you cannot find a kit locally, contact us
and we will provide you with the name of a dealer near you. If you will utilize the
mounting channel you must ensure that it is mounted on a flat surface so that the
three major sections (motor, drum and gear housing) are properly aligned. Proper
alignment of the winch will allow even distribution of the full rated load.
2. Start by connecting the roller fairlead to the winch using 2 each of the cap screw and
lock washer; If your winch is with the mounting channel, then using 2 each of the
cap screw, flat washer, lock washer and securing with locknut (Make sure the screw

5
is placed through the mounting channel and roller fairlead from inside the channel.
This will allow enough clearance for the winch to be placed in the channel without
obstruction.)
3. Assemble the winch to the mounting channel or vehicle bump base by first pulling
and releasing the clutch knob to the “CLUTCH OUT” position (free spooling). Pull
out a few inches of cable from the drum and feed the wire loop through the opening
in the front of the mounting channel and roller fairlead. Now, using the remaining
cap screws and lock washer secure the winch to the mounting channel.
4. Please refer to installation illustration.
Mounting The Directional Solenoid Valve Assembly:
The valve should be mounted away from any areas where heat may be considered
too extreme, such as an exhaust manifold or turbo. Be sure all plumbing and wiring
reaches from the area is selected without being stressed. It may be mounted by using
the bracket and allen screws supplied. Using the bracket as a guide, mark the location
of where the mounting holes are going to be drilled, remove the plate and drill four
1/4" holes. Mount Valve Assembly using nuts, bolts.
If your winch is U type, the directional solenoid valve is combined to hydraulic motor
already.
Note: On some vehicles grill may have to be removed to install plumbing and wiring
for the winch.
Electrical Connections:
If winch’s power supply is from the vehicle’s exiting power steering pump, the solenoid
valve system is designed default to the power steering box so power steering is
always available even when the winch is in use. The power source to the solenoid is
not energized until the three or four pole quick connector plug is plugged in. Each
solenoid has two wires-either of which can be used as a ground or for electric power.
The grounds are connected to each other at the factory . Connect all wiring to the
battery as shown in illustration. Then test hand control unit, solenoids will make a
slight “click” sound if connected properly.
Plumbing Connections:

6
Keep all hoses away from any areas where heat may be considered too extreme such
as an exhaust manifold or turbo. Lines should not be allowed to rub on any abrasive
or vibrating surfaces. In some applications, 90°fittings on the directional valve and
motor or balance valve are necessary to make hose mounting more flexible. After
plumbing has been laid out on vehicle, install o-ring fittings supplied to valve. Torque
tight. Do not over tighten any fittings. Install o-ring fittings on Winch Motor. Torque
tight. Connect any hose port A on motor to port A on directional valve, port B on motor
to port B on directional valve, port P on directional valve to pump’s high pressure port,
port T on valve to reservoir, if necessary connect any hose port S on valve to steering
box. Attach any o-ring or seal from vehicles original tube fitting to tube fitting.
Working hydraulic principle chart and installation illustration（YD）:

7
Below is installation illustration with mounting channel:
1. HWH 1 2 0 0 0 lb / HWH15000 lb / HWH 1 8 0 0 0 lb ：
2. HWHS1 2 000 lb ：
3. H W H S 0 8 0 lb ：

8
Caution:
Hydraulic system needs a relief valve to make sure the system is safe; If there is not
relief valve in the system; it would be serious danger and the system can’t operation. If
your winch drived by an existing hydraulic power system, the relief valve is also
existing.
Battery cables should not be drawn taut leave slack for some cable movement.
If your application is supplied with an added cooler, Please refer to illustration.
Check fluid level. Replace lost fluid to system. System will need to be purged. Start
engine. Power winch cable in 5 feet. Shut engine off. Check fluid level. Add fluid until
full. Start engine. Power winch cable out 5 feet. Shut engine off. Check fluid level. Add
fluid until full if necessary. Start engine. Power wrings cable into desired position. Turn
vehicle wheels from lock to lock position 5 times. This will aid in bleeding out any air
the may have got into the system.
If the hand control unit is working backwards, simply exchange the brown and white
wire connectors in valve.
Test Winch for proper operation. Refer to the Operation section, below.

9
OPERATION
WARNING
1 Make sure clutch is totally engaged before starting any winch operation;
2 Stay clear and away from raised loads;
3 Stay clear of cable while pulling do not try to guide cable;
4 A min. of 5 wraps of cable around the drum barrel.
General information:
The Winch’s standard equipments contain gear reducer、drum、hydraulic motor、
solenoid valve、switch assembly、female connector and plumbing fittings. The winch
obtains its pressure from the vehicle’s existing power steering pump or other hydraulic
power. The winch is totally sealed, can be used underwater.
For your reference there are several other ways to supply power for winch; the first
way: use an individual pump for engineering use; the second way: The winch’s
pressure is from the vehicle’s exiting power steering pump as Installation illustration:
①Use a suitable individual pump which has not oil valve; it supply pressure for both
steering box and winch. ②: Use a combined pump which integrate an oil valve
together, the oil valve supply two kinds of flow for difference demand, one with
constant flow is for steering use, the other with higher power is for engineering use.
Caution:
Hydraulic system needs an relief valve to make sure the system is safe; If there is not
relief valve in the system; it would be serious danger and the system can’t operation. If
your winch drived by an existing hydraulic power system, the relief valve is also
existing.
Winch working demonstration:
1. Disengage the clutch by turning the clutch to the “CLUTCH OUT”position.
2. Grab the cable assembly and pull the cable to the desired length, then attach to
item being pulled.

10
Caution: Always leave at least five turns of cable on the drum; Review Winch Safety
Warnings and Precautions on page 2、3 before continuing.
3. Reengage the clutch by turn the clutch assembly to the “CLUTCH IN”position, if
the clutch is not engaged, the winch drum must be turned by hand, until the clutch
is totally engaged.
4. Insert the switch assembly connector onto the directional valve
5. Test-run winch in two directions, each direction last one or two seconds, to test
whether winch working normally in two directions, meantime make sure the clutch
totally engaged.
6. While standing aside of the tow path, hold and operate the Switch Assembly
supplied by your choice. To reverse directions. Wait until the motor stops before
reversing directions.
7. When the towing is complete, remove the switch assembly. From the female
connector of the directional valve and replace the female connector cover.
Maintenances
eWINCH ACCESSORIES YOU WILL NEED
NOT INCLUDED WITH YOUR WINCH
Gloves –For handling the wire rope and hook strap.
Anchor Strap/Chain –Tree saver anchor straps are made of high quality nylon with
high tensile strengths up to 15000lbs.
Heavy Blanket –place on the cable to absorb energy should the wire rope break.
RIGGING TECHNIQUES
Self-Recovery
Locate a suitable anchor such as a strong tree trunk or boulder.
Always use a sling as an anchor point. CAUTION Do not attach
the clevis hook back onto the cable as this could cause damage to
the cable.As shown in Fig 3.1
Fig 3.1

11
CAUTION Do not winch from an acute angle as the wire rope
will pile up on one side of the drum causing damage to wire rope
and the winch. Fig 3.2
Short pulls from an angle can be used to straighten the vehicle.
Long pulls should be done with the wire rope at a 90° angle to the
winch/vehicle.
When pulling a heavy load, place a blanket or jacket over the wire
rope five or six feet from the hook. In the event of a broken cable it
will dampen the snap back. For additional protection open the
hood of the vehicle as shown in Fig 3.3
For pulls over 70% rated line pull, we recommend the use of the
snatch block/pulley block to double line the wire rope. Fig 3.4
This reduces the load on the winch and the strain on the rope by up
to 50% depending on the included angle.
WARNING - Never use your winch for overhead hoisting or for
lifting people or moving people.
LUBRICATION
1. All moving parts within the Winch having been Lubricated using high temperature
lithium grease at the factory. No internal lubrication is required.
2. Lubricate Cable Assembly periodically using a light penetrating oil.
CABLE ASSEMBLY REPLACEMENT
If the wire rope has become worn or is beginning to show signs of strands breaking, it
must be replaced before being used again.
1. Turning clutch to the “CLUTCH OUT”position.
Fig 3.2
Fig 3.3
Fig 3.4
Fig 3.5

12
2. Extend cable assembly to its full length. Note how the existing cable is
connected to the drum.
3. Remove old cable assembly and attach new one as the ld cable connected to
the drum. Insert the end of the new rope and secure the screw M8x10 being
tightly screwed
4. Turning clutch to the “CLUTH IN”position.
5. Retract cable assembly onto drum, first five wraps being careful not to allow
kinking, then winch cable must be wound onto the drum under a load of at
least 10% rated line pull.
WARNING - Only replace the wire rope with the identical replacement part
recommended by the manufacturer.
TROUBLE SHOOTING
SYMPTOM
POSSIBLE CAUSE
SUGGESTED ACTION
Winch does not
turn
-Electrical connections
have not connected
properly
-Insert Switch Assembly all the way into
connector.
-Tighten nuts on all cable connections.
Motor runs but
Cable drum
does not turn
- The clutch is Not
engaged
-Turn the clutch to the high or lows peed
position. If problem still persists, a qualified
technician needed to check and repair.
Winch drum
runs slowly or
without normal
power.
-Insufficient pressure or
oil flow
- Insufficient fluid in the
system
-Bump is not suitable or defective. Change a
new one or a suitable one
-Check fluid level. Add fluid until full.

13
Winch working
direction is in
backwards of
the switch
assembly.
-Electrical connections
are in wrong direction in
the valve solenoid.
-Simply exchange the blue and yellow wire
connectors at the solenoid of directional
valve, or change the oil pipe between the
valve and motor.
Winch braking
malfunction.
-Winch working in wrong
direction.
-Brake slice worn or
worn not.
-Change winch working direction looking is to
clockwise look at the motor end
- Simply readjusted the braking angle or
replaces the new brake slice.
WARNING - Adjustment braking angle method: The spring according to the
spring gyrotropic pre-tight two laps, then shows the spline tooth set according to
following braking cutaway view the adjustment angle for 20°±5°.

14
WINCH ASSEMBLY DRAWING( BST H )
OUT
IN

15
WINCH PARTS LIST(BST H)
No.
Part #
Qty
Description
Remark
1
HWH1200001
2
Screw M12×30
UsedinHWH12000/HWH15000/HWH18000lb
2
HWH1200002
2
Lock Washer Ø12
UsedinHWN12000/HWH15000/HWH18000lb
3
HWH1200100
1
Hydraulic Motor
Used in HWH12000/ HWH15000lb
HWH1800100
1
Hydraulic Motor
Used in HWH18000lb
4
HWH1200003
4
Screw M8×25
UsedinHWH12000/HWH15000/HWH18000lb
5
HWH1200004
4
Lock Washer Ø8
UsedinHWH12000/HWH15000/HWH18000lb
6
HWH1200005
1
Coupling plate
UsedinHWH12000/HWH15000/HWH18000lb
7
HWH1200006
1
Front Bearing
Used in HWH12000/ HWH15000lb
HWH1800006
Used in HWH18000lb
8
HWH1200007
2
Bushing-Drum
Used in HWH12000/ HWH15000lb
HWH1800007
Used in HWH18000lb
9
HWH1200200
1
Break/Shift Assembly
Used in HWH12000/ HWN15000lb
HWH1800200
Used in HWN18000lb
10
HWH1200008
1
Transition Shaft
Used in HWH12000/ HWH15000lb
HWH1800008
Used in HWH18000lb
11
HWH1200009
1
Transmission Shaft
Used in HWH12000/ HWN15000lb
HWH1800009
Used in HWH18000lb
12
HWH1200300
1
Drum Assembly
Used in HWH12000/ HWN15000lb
HWH1800300
Used in HWH18000lb
13
HWH1200010
1
Screw M8×10
UsedinHWH12000/HWH15000/HWH18000lb
14
HWH1200011
1
Inner supporting
Used in HWH12000/ HWH15000lb
HWH1800011
Used in HWH18000lb
15
HWH1200012
1
“O” Ring Seals
Used in HWH12000/ HWH15000lb
HWH1800012
Used in HWH18000lb
16
HWH1200013
1
Gear-Ring
Used in HWH12000/ HWH15000lb
HWH1800013
Used in HWN18000YD
17
HWH1200400
1
Gear Carrier Assembly(Output)
Used in HWH12000/ HWN15000lb
HWH1800400
Used in HWH18000lb
18
HWH1200500
1
Gear Carrier Assembly (Input)
Used in HWH12000/ HWN15000lb
HWH1800500
Used in HWH18000lb
19
HWH1200014
1
Antifriction Pad
Used in HWH12000/ HWH15000lb
HWH1800014
Used in HWH18000lb
20
HWH1200015
1
Screw M8×10
UsedinHWH12000/HWH15000/HWH18000lb
21
HWH1200600
1
Clutch handle Assembly
UsedinHWH12000/HWH15000/HWH18000lb

16
22
HWH1200016
1
Gear-Housing
Used in HWH12000/ HWH15000lb
HWH1800016
Used in HWH18000lb
23
HWH1200002
4
Lock Washer Ø12
UsedinHWH12000/HWH15000/HWH18000lb
24
HWH 1200001
4
Screw M12×35
UsedinHWH12000/HWH15000/HWH180000lb
25
HWH 1200017
4
Tamper
UsedinHWH12000/HWH15000/HWH180000lb
26
HWH 1200018
4
Screw M10×35
UsedinHWH12000/HWH15000/HWH180000lb
27
HWH 1200019
2
Tie Bar
UsedinHWH12000/HWH15000/HWH180000lb
28
HWH 1200020
4
Lock Washer Ø10
UsedinHWH12000/HWH15000/HWH180000lb
29
HWH 1200700
1
Remote Control Switch（RCH）
UsedinHWH12000/HWH15000/HWH180000lb
30
HWH 1200800
1
Cable Assembly
Used in HWH12000/HWH15000
HWH 1800800
Used in HWH18000lb
31
HWH 1200021
1
Strap
UsedinHWH12000/HWH15000/HWH180000lb
32
HWH 1200002
4
Lock Washer Ø12
UsedinHWH12000/HWH15000/HWH180000lb
33
HWH 1200022
4
Screw M12×20
UsedinHWH12000/HWH15000/HWH180000lb
34
HWH 1200900
1
Roller Fairlead
UsedinHWH12000/HWH15000/HWH180000lb
35
HWH 1201000
1
Mounting Channel
Used in HWH12000/ HWH15000lb (By Choice)
HWH 1801000
Used in HWN18000lb (By Choice)
36
HWH 1200023
2
Cap Screw M12×35
By Choice
37
HWH 1200024
2
Think Flat Washer Ø12
By Choice
38
HWH 1200002
2
Lock Washer Ø12
By Choice
39
HWH 1200025
2
Locknut M12
By Choice
40
HWH 1201300
1
Tensioned Of Steel Wire Supplied Assembly
Used in HWH12000/ HWH15000lb
HWH 1801300
Used in HWH18000YD
41
HWH 1200026
4
Lock Washer Ø10
By Choice
42
HWH 1200027
4
Screw M10×25
By Choice
43
HWH 1200028
1
Back Mounting Plata
By Choice
44
HWH 1200029
4
Lock Washer Ø12
By Choice
45
HWH 1200030
4
Screw M12×30
By Choice
46
HWH 1200031
2
Tie Bar
Used in HWH12000/ HWH15000lb
HWH 1800031
Used in HWH18000lb

17
WINCH ASSEMBLY DRAWING
BST HS 12000
456
1
78910 911 12 13 14 15
18 19
21 22 23
20
24 25 26
29 30 22 23 31
34
35 36 35 37 38 39 40 41 42 43 44 31 32
32 33
49
48
47
45
46
25
2
3
17
27 28
16

18
WINCH PARTS LIST BST HS 12000
No.
Part #
Qty
Description
Remark
1
HS1200001
1
High-pressure oil tube
2
HS1200002
2
Oil connection
3
HS1200003
2
Combination Washer 14
4
HS1200004
2
Cap Screw M12 x 30
5
HS1200005
2
Lock Washer Φ12
6
HS1200100
1
Hydraulic Motor
7
HS1200006
1
Blanced valve
8
HS1200007
4
Cap Screw M8 x 55
9
HS1200008
12
Lock Washer Φ8
10
HS1200009
8
Screw M8 x 30
11
HS1200010
1
Brake stents
12
HS1200011
3
Brake block
13
HS1200012
2
Friction plate
14
HS1200013
2
O-ring seal 100*3.55
15
HS1200014
1
Piston
16
HS1200015
1
O-ring seal 140*2.65
17
HS1200016
2
Disk spring
18
HS1200017
2
O-ring seal 118*3.55
19
HS1200018
1
Motor bracket
20
HS1200019
1
Coupling
21
HS1200020
1
Transmission shaft
22
HS1200021
2
Bearing bush
23
HS1200022
2
Ring Seals
24
HS1200023
8
Screw M10 x 25
25
HS1200024
16
Lock Washer Φ10
26
HS1200025
1
Stand bar（b）
27
HS1200026
1
Stand bar（a）
28
HS1200027
2
Screw M8 x 15
29
HS1200200
1
Drum Assembly
30
HS1200028
1
Coupling Ⅰ
31
HS1200029
16
Cap Screw M6 x 20
32
HS1200030
16
Lock Washer Φ6
33
HS1200031
1
End Bearing
34
HS1200300
1
Gear Carrier Assembly （Output）
35
HS1200032
2
Gasket
36
HS1200033
1
Gear-Ring（Output）
37
HS1200400
1
Gear Carrier Assembly （Input）
38
HS1200034
1
Circlip for hole Φ125
39
HS1200035
1
Gear-Ring（Input）
40
HS1200036
1
Gear—Input Sun
41
HS1200037
1
Trust Washer
42
HS1200038
1
Axle sleeve
43
HS1200039
1
Cover-Gear Housing
44
HS1200500
1
Clutch Assembly
45
HS1200040
8
Screw M10 x 35
46
HS1200041
8
Think Flat Washer Φ10
47
HS1200600
1
Roller Fairlead
48
HS1200700
1
Cable Assembly
49
HS1200800
1
Tensioned Of Steel Wire Supplied Assembly