KOZMAKSAN KHW Series Troubleshooting guide

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KHW SERIES
HYDRAULIC WINCH
USER AND SERVICE MANUAL
KHW 12000 • KHW 15000

2
CONTENTS
INTRODUCTION, SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
GENERAL LOAD PULLING RULES
INSTALLATION
CAUTION
OPERATION
WINCH ACCESSORIES YOU WILL NEED - RIGGING TECHNIQUES
LUBRICATION - CABLE ASSEMBLY REPLACEMENT
TROUBLE SHOOTING
WINCH ASSEMBLY DRAWING
WINCH PARTS LIST
WARRANTY TERMS
CERTIFICATES
3
4-5
6-7
8-9-10
11
12
13
14
15
16
17
18
19
PLEASE BE SURE TO READ THIS MANUAL CAREFULLY
BEFORE STARTING TO USE THE HYDRAULIC WINCH!
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INTRODUCTION
This Hydraulic winch has been manufactured solely for load pulling purposes within the
specified capacity range. Do not use it for lifting.
ABOUT THE MANUAL
This user and service manual comprises of general maintenance and user instructions
for the Hydraulic winchs, of which brand is “Kozmaksan”. Be sure to read this manual
carefully before starting to use the Hydraulic winch. Follow the maintenance and safety
instructions in this manual in order for a safe and long life-cycle. Where you encounter
a situation that is not addressed in this manual, please contact to representative of
“Kozmaksan”.
SAFETY INSTRUCTIONS
WARNING!!!
PLEASE READ AND FOLLOW ALL THE SAFETY INSTRUCTIONS IN ORDER TO
PREVENT THE ACCIDENTS AND INJURIES!
➢Do not start using any controlling and usage apparatus before getting familiar with them.
➢Keep this manual in a safe place for general maintenance instructions.
➢Rupture of the rope or an unexpected movement of the load may lead to fatal accidents.
Therefore, be sure to keep the working area clear of any people.
➢Do not use the empty-loaded lever when the Hydraulic winch is under load.
➢Otherwise, it may lead the load to loose and also to accidents.
➢When the drum is under load, do not control it with sudden movements.
➢Otherwise, it may lead the drum to be damaged or to accidents.
➢Keep away from moving parts, moving rope and load.
INTRODUCTION, SAFETY INSTRUCTIONS
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SAFETY INSTRUCTIONS
➢Be sure that the operating site and the surrounding area of the load is clean before starting
the pulling process.
➢Do not use the Hydraulic winch under the influence of alcohol and drugs.
➢Use the accessories and spare parts that are recommended by the manufacturer only.
➢In case of detecting any noise or vibration out of the Hydraulic winch, cease the operation
immediately and check the system.
➢Do not use the Hydraulic winch for any other purposes than those designated for it.
➢Do not try to hoist loads that exceed the capacity of the Hydraulic winch.
➢Do not try to hoist the load from right side or left side of the Hydraulic winch under no
circumstances. Use the steering tackle where deemed required.
➢Keep the pulling route clear of any obstacles.
➢Take any and all the conditions such as the elevation, surface texture, load state (wheeled,
draggable, etc.) into consideration before starting the operation.
➢Always fix the rope to a sturdy point of the load.
➢Be sure to wear all the protective personal equipment such as gloves, helmet, irontipped
shoes etc., before starting the operation.
➢Check the anchor bolts, hydraulic connections and the rope of the Hydraulic winch before
starting the operation.
➢Change the rope of the drum if it is damage.
It is a must to keep the last five (5) winding over the Hydraulic winch.
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SAFETY INSTRUCTIONS
Be sure to keep a safe distance from the operation site, in that
the rope may rupture, thus leading to fatal accidents.
Under no circumstances should you lift people with the
Hydraulic winch!
Wear the protective goggles.
Always wear the helmet.
Always wear the gloves.
Always wear the iron-tipped protective shoes.
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GENERAL LOAD PULLING RULES GENERAL LOAD PULLING RULES
Pulling Angle
Hoist the load with a maximum of 15o angle (horizontally) in order to ensure a long life-cycle
for the rope. Where the pulling is performed from vertical angles, the rope will not properly
wind to the drum, thus getting damaged.
Pulling Capacity
The Hydraulic winchs are always categorized based on the pulling capacity on the lowermost
winding of the drum. Therefore, take this detail into consideration when deciding to buy a
drum. The hoisting capacity and speed change based on the number of rope winding. The
drum has the highest hoisting capacity and lowest hoisting speed on the lowermost winding.
On the other hand, the drum has the lowest pulling capacity and highest winding speed on the
upmost winding.
HOISTING ANGLE
UPMOST (TOP) WINDING
MIDDLE WINDING
LOWERMOST (BOTTOM) WINDING
DRUM FLANGE
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GENERAL LOAD PULLING RULES
The Required Pulling Force
In addition to the weight of the load, factors such as the slope and the surface texture may
increase the weight of the same while pulling the load. The surface texture may be
categorized as mud, sullage, sand or gravel. Therefore, you can find the required pulling
force using the following calculation methods and tables through these factors before
starting the pulling process.
RPF = (Wt x S) + (Wt x G)
RPF: Required Pulling Force
Wt: Weight of the load
S: Ground based surface friction coecient
G: Slope coecient
For example, the required pulling force can be calculated as follows for a 3000 kg of vehicle
with a slope ratio of 100%, as stuck to sullage:
Wt: 3,000 kg, S: 0.625, G: 0.71
RPF = (Wt X S) + (Wt X G)
= (3,000 kg X 0.625) + (3,000 kg X 0.71)
= 1,875 kg + 2,130 kg
= 4,005 kg Required pulling force
SLOPE
HEIGHT
DISTANCE
5 30 0,06
ASPHALT 0,050
SLOPE
%
Angle
(0)
Slope
Coecient (G)
Surface
Type
Friction
Coecient (S)
10 60 0,11
GRASS 0,175 20 110 0,2
GRAVEL 0,250 30 170 0,3
SAND 0,325 50 260 0,44
MUD 0,425 70 350 0,58
SULLAGE 0,625 100 450 0,71
θ
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INSTALLATION
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 mostpopular vehicle and
mounting channels. If you cannot find a kit locally, contact usand we will provide you with
the name of a dealer near you. If you will utilize themounting channel you must ensure that it
is mounted on a flat surface so that thethree major sections (motor, drum and gear housing)
are properly aligned. Properalignment 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 andlock
washer; If your winch is with the mounting channel, then using 2 each of thecap screw, flat
washer, lock washer and securing with locknut (Make sure the screw 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.
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INSTALLATION
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:
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.
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INSTALLATION
Working Hydraulic Principle Chart And Installation Illustration
Below is Installation Illustration With Mounting Channel:
KHW 12000 lb / KHW 15000 lb
Tensioned of steel wire
supplied assembly
Back mounting plate
Winch
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CAUTION
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 o. Check fluid level. Add fluid until
full. Start engine. Power winch cable out 5 feet. Shut engine o. 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.
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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: (1) Use a suitable individual pump which has not oil valve; it supply pressure for
bothsteering box and winch. (2) Use a combined pump which integrate an oil valve together,
the oil valve supply two kinds of flow for dierence 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 toitem being
pulled.
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, ifthe clutch is
not engaged, the winch drum must be turned by hand, until the clutchis 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 testwhether
winch working normally in two directions, meantime make sure the clutchtotally engaged.
6. While standing aside of the tow path, hold and operate the Switch Assemblysupplied by your
choice. To reverse directions. Wait until the motor stops beforereversing directions.
7. When the towing is complete, remove the switch assembly. From the femaleconnector of the
directional valve and replace the female connector cover.
OPERATION WINCH ACCESSORIES YOU WILL NEED - RIGGING TECHNIQUES
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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.
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. 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
For pulls over 70% rated line pull, we recommend
the use of the snatch block/pulley block to
double line the wire rope. 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.
WINCH ACCESSORIES YOU WILL NEED - RIGGING TECHNIQUES
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LUBRICATION:
1. All moving parts within the Winch having been Lubricated using high
temperaturelithium 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.
2. Extend cable assembly to its full length. Note how the existing cable isconnected to
the drum.
3. Remove old cable assembly and attach new one as the ld cable connected tothe drum.
Insert the end of the new rope and secure the screw M8x10 beingtightly screwed
4. Turning clutch to the “CLUTH IN” position.
5. Retract cable assembly onto drum, first five wraps being careful not to allowkinking,
then winch cable must be wound onto the drum under a load of atleast 10% rated line
pull.
WARNING: Only replace the wire rope with the identical replacement part
recommended by the manufacturer.
LUBRICATION - CABLE ASSEMBLY REPLACEMENT TROUBLE SHOOTING
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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°.
TROUBLE SHOOTING
Winch does not turn
Motor runs but cable drum
does not turn
Winch drum runs slowly or
without normal power.
Winch working direction is
in backwards of the switch
assembly.
Winch braking
malfunction.
• Electricalconnections
have not connected
properly
• The clutch is not engaged
• Insucient pressure or
oil flow
• Insucient fluid in the
system
• Electrical connections
are in wrong direction in
the valve solenoid.
• Winch working in
wrong direction.
• Brake slice worn or
worn not.
• Insert Switch Assembly all
the way intoconnector
• Tighten nuts on all cable
connections.
• Turn the clutch to the
high or lows peed position.
If problem still persists, a
qualified technician needed to
check and repair.
• Bump is not suitable or
defective. Change anew one
or a suitable one
• Check fluid level. Add fluid
until full.
• Simply exchange the blue
and yellow wire connectors at
the solenoid of directional
valve, or change the oil pipe
between the valve and motor.
• Change winch working
direction looking is to
clockwise look at the motor
end
• Simply readjusted the
braking angle or replaces the
new brake slice.
PROBLEM CAUSE SOLUTION
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WINCH ASSEMBLY DRAWING
1
2
3
4
5
6
7
8
9
10
11
12
14
30
28
29
29
28
13
13
15
16
17
18
19
22
21
20
26
32
33
36
35
23
24
34
31
25
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529
261
225,00
256
72,00
178,00
27

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WINCH PARTS LIST
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
2
2
1
4
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
4
4
1
1
2
4
4
2
1
4
4
1
4
4
Screw M12×30
Lock Washer Ø12
Hydromotor
Screw M8×25
Hydromotor plate
Back Housing
Coupling
Coupling
Spline
Break/Shift Package
Transition Shaft
Transmission Shaft
Dust seal
Drum
Plate
“O” Ring Seal
Center Gear
Planetary Gear Set
Planetary Gear Set
Plastic Stopper
Manual Neutral-Loaded Lever
Gear-Housing
Lock Washer Ø12
Screw M12×20
Roller Fairlead
Set Screw M8×10
Toraco Bar
Screw M10×35
Lock Washer Ø10
Steel Tie Bar
Back Mounting Plate
Screw M10×25
Lock Washer Ø10
Rope Stabiliser
Screw M12×30
Lock Washer Ø12
No Qty Description
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➢Where the Crane is brought in pieces, it will not by covered under the warranty.
➢No part that has experienced an accident is covered under the warranty.
➢Failure of a product due to taking or replacing a part of the change is not covered under the
warranty.
➢The cranes that are recognized to have been misused are not covered under the warranty.
➢The Crane can only be used for rescue purposes. Those that are used for any other purposes
are not covered under the warranty.
➢This warranty covers the manufacturing defects, workmanship and material faults, along with
the mechanical parts.
➢The steel rope and the hook is not covered under the warranty.
➢The scope of the warranty does not cover the standard wear-out and abrasion, Crane
accidents, misuse, crash, overloading, modification, malpractices, faulty assembly situations.
➢It is a must for the customer to detach the Crane and deliver it to the plant with the shipping
company as determined by “Kozmaksan”.
➢All the shipping costs shall be covered by the crane owner.
➢The owner of the product shall be responsible for any and all the shipping costs until it is
accepted that the problem in the product is covered under the warranty. In the event that the
problem will be solved once the part that is deemed required to be changed is sent to the
owner, the spare part shall be sent to the “product owner” at his/her own cost. Under such
circumstances, “Kozmaksan” may request the broken parts to be sent. “Kozmaksan” reserves the
right to make changes on the Warranty Terms.
WARRANTY TERMS
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19
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CERTIFICATES

www.kozmaksan.net
KozmaksanPTO
kozmaksanpto
18407234
kozmaksan1
www.kozmaksan.net
[e-mail]
1. Organize Sanayi Bölgesi
Erkunt Cad. No: 6 Sincan
Ankara - TURKEY
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