WARRIOR 260EHLW12 User manual

ELECTRICAL HOIST
260EHLW12
260EHLW24
Assembly & Operating Instruction

CONTENTS
INTRODUCTION...................................................................................... 1
DANGER...................................................................................................2
HOIST ASSEMBLY AND MOUNTING.....................................................5
MOUNTING DRAWING............................................................................6
HOIST WORKING DEMONSTRATION....................................................6
REPLACING THE WIRE ROPE ...............................................................7
MAINTENANCE........................................................................................7
TROUBLE SHOOTING.............................................................................9
HOIST ASSEMBLY DRAWING .............................................................1 0
HOIST PARTS LIST...............................................................................1 1
SPECIFICATION....................................................................................1 2

1
INTRODUCTION
Congratulations on your purchase of a high quality winch. We design
and manufacture lifting winches to strict specifications, with proper use
and maintenance it will bring you many years of satisfying service.
WARNING - Read, understand and follow all danger, warning and
cautions instructions before operating this device. Failure to read
and follow these instructions may result in personal injury and/or
property damage.
Follow these general safety precautions:
•Confirm that the winch complies with the correct application.
•Ensure winch is secure and the rope is correctly wound on to
the drum.
•Do not use unsuitable pulleys or accessories.
•Do not use unsuitable rope if construction is weak strength or
has any defects.
•Pay attention to the earthing, it provides a path of least
resistance for electric current to reduce the risk of shock.
•Check the winch for smooth operation without load before
loading operation.
•Make sure the wire rope is wound evenly on the first layer on
the drum, unwind if mixed crossed windings occur.
1.The winch MUST never be used to lift, support or otherwise
transport people or animals.
2. The winch is NOT a load bearing / securing device and MUST
never hold a load for long periods of time or used for anchoring
transported pieces of equipment.
2. A minimum of five (5) wraps of rope around the drum at all times
is necessary to support the rated load.
3. We take no responsibility for the subsequent or poor performance
of this winch if oil or grease properties other than recommended are

2
used or any accident occurs through not reading and following the
these safety instructions.
DANGER
The following environmental conditions may
result in the possible causes of winch problems.
-Low temperature below -10°C, high temperature above 40°C
or humidity above 90% conditions.
-In heavy acid or salty conditions.
*Cause malfunction of spare pares.
-Exposed to rain or snow
*Cause rust or short circuit.
-In a organic chemistry or explosive power conditions.
*Cause explosion.
-In a heavy general powder conditions.
*Cause malfunction of performances.

3
SAFETY PRECAUTIONS
Always Pay attention to the following instructions. Obvious
mistakes in operation may result in personal injury or equipment
damage.
WINCH ASSEMBLY AND MOUNTING
1. Your winch is designed with a bolt pattern that is standard in this class of lifting
winch. Many winch mounting kits (Sold Separately) are available that utilize
this bolt pattern for the mounting channels. 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 lifting winch will allow even distribution of the full rated load.
2. Pull out a few inches of cable from the drum. Now, using the remaining cap
screws, flat washer, lock washer and nut secure the hoist to the mounting
channel (Sold Separately)
3. Connect the battery and motor leads as the drawing above. Keep in mind that
every type of winch is different each other.
4. Assemble the clevis hook to the cable. Take off the pin from the clevis hook,
connect the clevis hook to the cable and mount the pin back to the clevis Hook.
5. Always use the hand saver (If Supplied) when free-spooling and re-spooling the
wire rope. Using the hand saver keeps your hands and fingers away from the
rotating drum.
6. Check for proper drum rotation. Pull out some cable from the drum. Press the
cable out button on the remote lead. If the drum is turning in the correct
direction releasing more cable then your connections are correct. If the drum is
turning and collecting more cable then the direction is incorrect and reverse the
leads on the motor. Repeat and check rotation.

4
MOUNTING DRAWING
The mounting drawing
CAUTION –Batteries contain gases which are flammable and explosive. Wear
eye protection during installation and remove all jewelry. Do not lean over
battery while making connections.
WINCH WORKING DEMONSTRATION
1. Grab the cable assembly and pull the cable to the desired length, then attach to
item being pulled.
Caution: Always leave at least five turns of cable on the drum; Review hoist safety
warnings and precautions on page 2,3 before continuing.
2. Insert the remote lead switch assembly plug into the control box socket.
3. Test-run winch is both forward and backwards directions, each direction for one or
two seconds.

5
4. While standing aside of the tow path, hold and operate the remote lead switch
assembly supplied by your choice. To reverse directions. Wait until the motor stops
completely before reversing directions.
5. When the pulling is complete, remove the remote lead switch assembly. From the
female connector of the directional valve and replace the female connectors cover.
REPLACING THE WIRE ROPE
If the wire rope has become worn or is beginning to show signs of damage, it must be
replaced before being used again.
1. Extend cable assembly to its full length. Note how the existing cable is connected
to the drum.
2. Remove old cable assembly and attach new one as the old cable connected to the
drum. Insert the end of the new rope and secure the screw.
3. Ensure that the new cable wraps in the same rotation direction as the old one.
The cable should leave the drum from the bottom, under the drum.
4. Retract Cable Assembly onto drum, first five wraps being careful not to allow
kinking, then steel cable must be wound onto the drum under a load of a light load.
WARNING - Only replace the wire rope with the identical replacement part
recommended by the manufacturer. Contact service agent.
MAINTENANCE
1. Periodically check the tightness of mounting bolts and electrical connections.
Remove all dirt or corrosion and always keep clean.
2. Do not attempt to disassemble the gear box. Repairs should be done by the
manufacturer or an authorized repair center.
3. The gearbox has been lubricated using a high temperature lithium grease and
is sealed at the factory. No internal lubrication or maintenance is required.

6
Classification of checks
Checking Item
Checking Method
Checking Reference
Daily
Periodical
One
month
Three
month
One
year
◎
Breaking of base wire
Visual
Less than 10%
◎
Decreasing of diameter
Visual
7% of normal diameter
max
◎
Kink phenomena
Visual
To be free from kink
phenomena
◎
Wire
Rope
Deforming or corrosion
Visual
To be not remarkable
◎
Fastening condition of end
Visual
To be sufficient for
hanging up of load
◎
Condition of rope
winding-in
Visual
To be free from irregular
winding
◎
◎
Drum
Drum and flange
Visual
No deformation
◎
Wear of drum
Visual
To be free from
remarkable wearing
◎
Switch
Wire
Visual
No damage
◎
“IN”and “OUT”
Visual
No abnormality
◎
Working direction
Visual
No abnormality in lifting
◎
Operation
Abnormal sound
Hear out
No abnormal sound
◎
Over load test
Working
Existence of abnormalities

7
TROUBLE SHOOTING
When the winch fails to operate after several attempts, or if there is any fault while
operating check the following:
Symptom
Possible Cause
Remedy
Hoist will not
operate
Cut circuit
Check battery lead
Weak battery
Recharge or replace battery (Minimum
650CCA)
Damaged circuit breaker
Replace circuit breaker
Bad connection of wirings
Reconnect tightly
Damaged solenoid
Replace solenoid
Cut circuit on switch
Replace switch
Damaged motor or worn carbon brush
Replace motor or carbon brush
Dropt or lost motor wiring
Tighten wirings
Motor runs in
one direction
Broken wiring or bad connection
Reconnect or replace wiring
Damaged or stuck solenoid
Replace solenoid
Switch inoperative
Replace switch
Dropt or lost wiring
Replace wiring and tighten wirings
Hoist won’t lift
rated load
Considerable voltage drop exceeds by 10% of the
rated voltage of 12V DC or 24V DC
Correct leads size
Replace battery as bad condition
Clean and tighten the wirings
No brake
Damaged brake cam and disc
Replace brake cam and disc
Damaged gear box
Replace gear box
Dropt snatch ring
Replace snatch ring
Oil leakage at brake
Clean oil leakage
Damaged or inoperative spiral spring
Replace and position spiral spring
Brake distance
is too long
Worn or damaged brake
Replace or adjust brake
Oil leakage at brake
Clean oil leakage
Damaged gear
train
Hit by certain exterior force
Replace the damaged components
Damaged gear train
Replace the damaged components
Over load operation
Replace a new hoist
Motor runs
extremely hot
Long period of operation
Allow to cool
Damaged motor
Replace or repair motor
Damaged or inoperative brake
Replace or repair brake
Hoist vibrates
badly, noisy or
does not hold a
load
Damaged brake
Replace or repair brake
Mounting surface is not flat
Make sure mounting surface is flat
Tie bar is bent
Replace tie bar

8
WINCH ASSEMBLY
DRAWING
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