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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