TOHO S Series User manual

Instruction Manual
Mini Electric winch
S-series,T-series,M-series
READY THIS MANUAL BEFORE USING THESE PRODUCTS
This manual contains important safety, installation, operation
and maintenance information. Make this manual available to all
persons responsible for the operation, installation and
maintenance of the mini electric winch.

Table of Contents 10. Part List
2
3
3
8
5
5
5
5
6
6
6
7
7
7
8
8
9
10
11
12
13
14
15
16
17
18
1.Specifications and Dimensions
2. Precautions
2.1 General Safety Precautions
2.2 Environmental Precaution
2.3 Handing Precautions
3.lnstallation
3.1 Winch Assembly
3.2 Mounting
3.3 Plug Insertion
4.Winch Principles
4.1 Percentage Duty Cycle (%ED)
4.2 Load Rated
4.3 Braking
4.4 Over-winding Lift Prevention
4.5 Reverse-Winding Prevention
5. Maintenance and Replacement
5.1 Carbon Brush Replacement
5.2 Wire Rope Replacement
5.3 Oil Lubrication
6.Checking Reference
7.Trouble Shootings
8. Wiring Diagram
9. Parts Drawing S-Series-160kg,180kg,230kg,250kg,300kg
Parts Drawing T-Series-160kg,180kg,230kg,250kg,300kg
Parts Drawing M-Series-160kg,180kg,230kg,250kg,300kg
Parts Drawing S-Series-280kg,360kg,500kg
Parts Drawing T-Series-280kg,360kg,500kg
Parts DrawingM-Series-280kg,360kg,500kg
10. Parts List
No.
37
38
39
40
40-1
41
42
43
44
44-1
45
46
47
48
49
50
51
52
53
54
54-1
55
56
57
58
59
60
61
62
63
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
No.
1
2
3
4
5
5-1
6
7
7-1
8
9
10
11
11-1
12
12-1
13
14
14-1
15
15-1
16
17
18
19
20
21
22
23
24
24-1
25
26
27
28
28-1
29
30
30-1
31
32
33
34
35
36
36-1
Parts description
MotorCover
Socket Bolt
Socket Bolt
Label
Rectifier Fixing Plate (M)
Screw (M)
Wiring Box Cover
Power Cable Connector
Screw
Contactor Fixing Plate (M)
Control Connector Fixing Plate
Micro Switch
Screw
Fixing Plate
Switch Cable Connector
Screw
Bearing
Rotator
Fan
AirGuiding Cover
PlasticTube
Circlip
Bearing
Oil Seal
Stator
Socket Bolt
Terminal Block(T)
Screw (T)
Electromagnetic Contactor(M)
Bridge Rectifier
Screw
Resistor
Screw
Wiring Rack
Screw
Washer
Limit Lever Fixing Plate
Limit Lever Fixing Plate
Screw 73 Bearing
Anti-reverse Reel Push Rod
Spring
Screw
Screw
Upper Hook Set
Socket Bolt
Upper hook Bolt Sleeve
Parts description
Nut
Reel Drum
Wire Rope Fixing Screw
Screw
Spring Washer
Wire Rope Side Cover
OutputShaft
key
Main Body Base
Sticker
Bearing
Circlip
First Reduction Gear
Key
First Reduction Pinion
Bearing
Bearing
Second Reduction Pinion
Brake Disk
Brass Ratchet Disc
Copper Washer
Second Reduction Gear
Spring Pin
Rotary Stop Plate
Circlip
Bearing
Gasket
Gear Cover
Oil Seal
Socket Bolt
Socket Bolt
Bearing
Circlip
Third Reduction Gear
Key
Third Reduction Pinion
Bearing
Oil Seal
Bearing
Circlip
Fourth Reduction Gear
Bearing
Pawl Screws
Pawl
Socket Bolt
Upper hook Bolt Sleeve
Part description
Screw
Upper Limit Holder
Spring
Wsahser
Upper Limit Push Rod
Washer
Nut
Upper Limit
Wire Rope
R Pin
Wire Rope Fixing Pin
Lower Hook Set
Carton Brush Base
Carbon Cable Fixing Screw
Carbon Base Cable
Carbon Brush
Carbon Brush Cover
O Ring
Carbon Brush Protection
Screw
Control Switch Set
Switch Cable
Switch Cable Connector
Power Cable Set
Power Cable with Plug
Power Cable COnnector
Cable Support
Cable Support Socket
Screw
Swithc Box
Sticker
Cable Fixing Plate
Screw
Internal Switch Contact
Screw
Switch Cover
Screw
PLT Cover Protection (T)
PLT Cover Protection (T)
Twin -Hole Hook
Clasp
Screw
Cable Fixing Clip
Switch without Cable
No.
81
82
83
83-1
83-2
83-3
83-4
84
85
86
87
88
89
89-1
89-2
90
91
92
92-1
92-2
93
93-1
93-2
94
94-1
94-2
95
95-1
97
98
98-1
99
99-1
100
101
102
103
104
105
106
107
108
109
114

9.Parts drawing M-Series
280kg,360kg,500kg
9.Soecifications and Dimensions
S-series T-Series M-series
Model
Rated Load
Lifting Heigth
Wire Rope Dia.
160kg/180kg/230kg/250kg/300kg
30m
5mm
280kg/360kg
60m
5mm
Motor
1200W
1300W
1500W
1600W
Lifting
Speed
50Hz
60Hz
Power
Duty
Internation Class
Insulation Class
Single-phase, 110V-220V, 220-240V, AC 50/60Hz
ED 25% Max. on time: 15min/hr. Max, number of starts: 150/hr
54
F
160kg
180kg/230kg/280kg
250kg
300kg/360kg/280kg
160kg/180kg/230kg/250kg/300kg
280kg/360kg/500kg
160kg/180kg/230kg/250kg/300kg
280kg/360kg/500kg
19m/min
13m/min
23m/min
15m/min
500kg
30m
6mm
160KG, 180KG, 230KG, 250KG, 300KG 280KG, 360KG, 500KG

2.Precautions
2.1 GeneralSafety Precautions
The winch has been designed to give safe and dependable service if operated according
to the instructions. Please read and understand this manual before installation and
operation of the winch.
Follow these general safety precautions:
●Confirm thatthe winch complies with the using conditions.
●Keep the winch secure strongly and the rope is notwound to be deviated tothe drum.
●Don't use unsuitable pulleys oraccessories concerned.
●Don't use unsuitable rope in construction, strength or having any defects.
●Pay attention to the grounding, it provides a path of least resistance forelectric
currentto reduce the risk of shock.
●Check the winch for smooth operation without load before loading operation.
●Make sure the wire rope to be wound evenly in the firstlayeron the drum, rewind it
if a mixed windings in existence.
●If a wire rope is found an uneven winding or accumulated at one side of the drum,
align it adequately.
WARNING
The following environmental conditions may result in the possible causes of
winch trouble.
● Lowtemperature below-10°, high temperature above 40° or humidity
above 90°/o conditions.
● In an organic chemistry or explosive power conditions.
● In heavy acid orsalty conditions.
● In the rain or snow condition.
● In a heavy general powder conditions.
1. The winch is notto be used to life, support or otherwise transport personnel.
2. A minimum of five (5) wraps of rope around the drum is necessary to supportthe load
rated.
3. The owner and lor the operator shall have an understanding of these operating
instructions and the warning before operating the electricalwinch. Failureto follow
these warnings may resultin loss of load, damage to the winch, property damage,
personal, orfatal injury.
4. The owner shall retain this manualforfurther reference to importantwarnings,
installation, operating and maintenance instructions.
2.2 Environmental Precaution
WARNING
9.Parts drawing T-Series
280kg,360kg,500kg

9.Parts drawing S-Series
280kg,360kg,500kg
2.Precautions
2.1 General Safety Precautions
The winch has been designed to give safe and dependable service if operated according
to the instructions. Please read and understand this manual before installation and
operation of the winch.
●To preventthe risk of electric shock, the power plug must be plugged into a matching
outlet and grounded in good condition.
●Nevertry to lift a load higherthan the rated cap.
●Never hitch a ride on the hook, sling orload being moving.
●Winches are notto be used forlifting orlowering people.
●Don'twork, walk or stand under an operating winch.
●Always remain in control. Never neglectthe winch while actually hoisting a load.
●While working, never stand under a lifting load or within the conveying area.
●Always look up when working around winch, there is potential danger overhead.
●Never gravitate a load free.
●Be sure to lifta load vertically. Slack may allowwires to be caught in The drum.
●Priorto starting of use, carry outthe daily checking withoutfail, and after confirming
the safety of function. If having a counter rotation incurred, make sure to correct
its rotation direction.
●Priorto lifting. Make sure to have a precise performance of brake. If any malfunction
of brake happened, stop the operation immediately.
●When load suspended in air, itwill not allowto be welding.
●Wire rope with one or more of the following defects shall be removed or replaced
immediately.
I) kink, 2) distortion, 3) corrosion, 4) Broken wires more than 1O°/,,
5). Decreasing of diameter more than 7°/,
●Stop the operation if there is any queer noise orvibration in the gear box
to be happened.
●Do not connectthe wire rope with the grounding of welding machine.
●While welding, do not have any contactwith the welding objects because of
having spark.
●Do not pullthe switch.
●Never plugging (instant reverse-winding) or inching.
●Do notoverthe shorttime ratings of the winch.
●ln orderto preventthe layer down due to overloosening of rope irregular winding,
etc., operate according to the suitable operating method.
●Use a winch byfixing so securelythatthe rope around the drum is even.
●Be sureto fix a rope in the centerof weight hook.
●Avoid catching the hook orlifting a load on a fixed obstruction.
●Always leave the pendant switch positioned immediately after use.
●Make sure thatthe load being lifting is well balanced and secured before starting.
●Avoid water splashes on the pendant switch.
●Neverwrap the load with the wire rope.

9.Parts drawing M-Series
160kg, 180kg, 230kg, 250kg, 360kg
3.Installation
3.1 Winch Assembly
Hanger
Winch body
Brush holder
Switch receptacle
Wire rope
Reverse winding
limit lever
Weight hook
Switch connector
Power plug
Over-windling
limit lever
Pendant switch
3.2 Mounting
The winch designed to be hanged ormounted on a firm orstable barora bracket. When
hanging, do not allow the body or load to be caught by any construction of frame, or
other obstruction. Be sure to lock the hangerfor extra safety.
3.3 Plug insertion
lnsertthe power plug into the power receptacle of the winch,
and clockwise tighten it byturning the locking ring.Be sureto
lockthe lead by a holder. Do notallow itto be caught by wire
rope, drum or other obstacle.
The length of powercord is subjecttothe distance of 20
meter, for any othercases, please use a bigger section cord
such as 2.0 mm or 3.5 mm ora magnetic switch equipped to
preventa considerable voltage drop to be happened.
Hanger
Hook
Hanger
Hook Bracket
Fixing
ring
Plug
Holder

8.Parts drawing T-Series
160kg,180kg,230kg,250kg,300kg
4.Winch principles
4.1 Percentage Duty Cycle
WA RNIN G Never hoist over the rated percentage duty cycle.
The life of the winch is depending on the conditions of the load and working frequency.
In the long time operation, make sure to use the machine within its shorttime ratings.
Shorttime ratings meansthe working duty cycle is subjectto the rated voltage, rated
frequency and a 63% of rated load.All mini winches are rated 25% percentage duty cycle.
percentage duty cycle= Operating hours %
Operating hours + stopping hours
4.2 Load Rated
Top layer (Max. speed Min.load)
Half layer (Med. speed Med. laod)
First layer (Min. speed Max.load)
4.3 Breaking
●Braking device is composed of a mechanic brake and an electronic generated brake.
The brake distance from thetime of braking until stopping completely should be within
1.5% of rope length to the wound in during 1 minute.
●Owing tothe rope speed on no load is 1.5-1.8 times faster than that on rated load,
the brake distance on no load will be longer, butstillwithin 1.5% of rope length.
●lt is highly recommended thatany adjustments are carried out by a qualified technician
at an authorized service center.
●Brake adjustment procedures.
Step 1. Remove retaining ring and spring pin.
Step 2. Tighten 3rd gear/4th shaft counter-clockwise until holding to the ratchet.
Step 3. Find the closed pole between spring pins and fit plate
(one between four selections), then putthe fix plate ontothe square hole
of 3rd or 4th shaft.
Step 4. Insert spring pins and lock retaining ring.
2nd/3rd Gear
ratchet
3rd/4th Shaft
Spring pin
Fix plate

4.Winch principles
4.4 Over-winding Lift Prevention
●A special mechanism prevents an over-winding
when lifting.
●When the weight hook touches the limit lever.
Lifting is automatically stopped.
●However, if the limit lever is set too close to the
winch body, itwill cause serious damage to the
limitleverand the winch body.
●A suggested distance (S) between the limitlever
and winch bottom is as follows.
4.5 Reverse-Winding Prevention
●A special mechanism prevents a reverse-winding
when lowering.
●When lowering, a wire rope is fully extended,
the wire rope will be shifted its position from O to X.
●When a wire ropetouches the limitlever of
over-winding prevention device. Lowing will be
automatically stopped.
●When the wire rope is shifted to the position of X,
pull itand press the T button to return its position to O.
70-90mm
Over-winding
limit lever
5.Maintenance and Replacement
5.1 Carbon Brush Replacement
WARNING
Clean the accumulated powder of carbon brush
periodically to ascertain the insulation resistance
upto1 MΩ
●lt is essentialto check the carbon brush periodically. If its
length is leftless than 7.5 mm resulting from wear, it is
absolute necessary to replace carbon brush immediately.
●While replacing, smoothly insert carbon brush into carbon
holderin the first place, then put brush cap into the hole.
●Before tightening the carbon brush holder, make sureto
position O-ring.
●Aset of carbon brush consists 2 piece of carbon brush.
Ascertain to replace 2 pieces of carbon brush on opposite
sides of winch body atthe same time.
carbon brush
holder
carbon brush
7.5
17
1.Parts drawing S-Series
160kg,180kg,230kg,250kg,300kg

8.Wiring Diagram
Control Circut for S-series
5.Maintenance and Replacement