HYDRAULIC WINCH
USER AND SERVICE MANUAL
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CONTENTS
PLEASE BE SURE TO READ THIS MANUAL CAREFULLY
BEFORE STARTING TO USE THE HYDRAULIC WINCH!
3 INTRODUCTION
3 SAFETY INSTRUCTIONS
6 GENERAL LOAD PULLING RULES
8 GENERAL ASSEMBLY INSTRUCTIONS
9 HYDRAULIC SYSTEM ASSEMBLY
10 ROPE ASSEMBLY
11 GENERAL USER INSTRUCTIONS
12 USE OF EMPTY-LOADED LEVER
13 USE OF PNEUMATIC EMPTY-LOADED LEVER
14 LOAD PULLING PROCESS
16 GENERAL MAINTENANCE
17 PROBLEM – CAUSE – SOLUTION TABLE
19 POINTS TO CONSIDER WITH REGARDS TO ROPE
20 WARRANTY TERMS AND WARRANT CERTIFICATE
21 CERTIFICATES
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INTRODUCTION, SAFETY INSTRUCTIONS
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 “TORAco”. 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
“TORAco”.
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.
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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
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.
HOISTING ANGLE
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.
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 coefficient
G: Slope coefficient
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
SLOPE Angle Slope
Surface Friction % (0) Coefficient (G)
Type Coefficient (S)
5 30 0,06
ASPHALT 0,050
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
RPF = (Wt X S) + (Wt X G)
SLOPE
= (3,000 kg X 0.625) + (3,000 kg X 0.71) HEIGHT
= 1,875 kg + 2,130 kg θ
= 4,005 kg Required pulling force
DISTANCE
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GENERAL ASSEMBLY INSTRUCTIONS
The Hydraulic winch can be assembled to a vehicles shown as follows. While assembling the
Hydraulic winch, be sure to follow the technical instructions specified in this manual for safe
use.
The assembly is made on a flat metal sheet. The thickness of the metal sheet on which the
Hydraulic winch is planned to be assembled must be at least 10-12mm (For THW-8K, THW-10K,
THW-12K, THW-15K, THW-16K, THW-18K Series)
The assembly is made on a flat metal sheet. The thickness of the metal sheet on which the
Hydraulic winch is planned to be assembled must be at least 15mm (For TORAco THW-22K,
TORAco THW-26K, TORAco THW-33KSeries)
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HYDRAULIC SYSTEM ASSEMBLY
Hydraulic system assembly
You can assembly the hydraulic connections as shown on the following drawings based on the
rope winding style.
For TORAco THW-8K, TORAco THW-10K, TORAco THW-12K, TORAco THW-15K, TORAco THW-
16K, TORAco THW-18K, TORAco THW-22K, TORAco THW-26K, TORAco THW-33K models.
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ROPE ASSEMBLY
Rope assembly
The rope assembly is based on the area where the Hydraulic winch is planned to be mounted.
• Where you plan to mount the Hydraulic winch on a metal sheet with a frontal pulley, you
must assemble the rope as shown in the drawing, and fix the rope passing under the Hydraulic
winch.
• If you mounted the Hydraulic winch using a bracket, the rope must be assembled as shown in
the drawing.
ALWAYS CHECK THE ROPE FIXING BOLT. LOOSE BOLTS MAY LEAD THE ROPE TO
DISPLACE, THUS CAUSING SERIOUS ACCIDENTS.
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GENERAL USER INSTRUCTIONS
GENERAL
This technical drawing is for TORAco THW-8K, TORAco THW-10K, TORAco THW-12K, TORAco
THW-15K, TORAco THW-16K, TORAco THW-18K models.
1- Manual or Pneumatic empty-loaded lever
2- Gearbox oil filler plug
2 1
3- Rope pressure pulley 3
4- Drum (pulley) 4
5
5- Brake body
6- Brake valve 11
7- Hydro-motor 6 10
8- Brake cap 7
9- Frontal quad steering pulley 9
10- Oil level controlling plug
11-Transmission body (gearbox)
CHECK THE FOLLOWING BEFORE STARTING THE PULLING OPERATION!
➢ Check all the hydraulic connection points for loose parts and leakages.
➢ Check if the rope is damaged.
➢ Check the hydraulic oil level from the oil tank.
➢ Make sure that there is no one present in the operation site.
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USE OF EMPTY-LOADED LEVER
Follow the following process to release a rope manually:
Pull the empty-loaded lever towards yourself as shown in the drawing with a 90o angle and
leave it there. The manual rope release lock is opened this way. Then, you can manually pull
the rope towards the load.
THE LAST FIVE (5) ROPE WINDING MUST BE LEFT OVER THE DRUM!
Follow the following process in order the take the Hydraulic winch to the pulling position:
Position the empty-loaded level as shown in the drawing. This will ensure the Hydraulic winch
to be locked. Then, you can start the pulling process by providing power to the Hydraulic winch
through the hydraulic controlling levers.
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USE OF PNEUMATIC EMPTY-LOADED LEVER
This technical drawing is for TORAco THW-22K, TORAco THW-26K, TORAco THW-33K series.
1- Manual or Pneumatic empty-loaded lever
2- Gear box oil filling plug
3- Rope pressure pulley
4- Drum (pulley)
5- Brake body
6- Brake valve
7- Hydro-motor
8- Brake cap
9- Frontal quad steering pulley
10- Oil level controlling plug
11- Transmission body (gearbox)
1
2
3
4
5
11
10
6
9
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LOAD PULLING PROCESS
USE OF PNEUMATIC EMPTY-LOADED LEVER
Follow the following process in order to release the manual rope pneumatically:
Apply pressurized air on the coupling over P point.
Follow the following process in order to take it to the pneumatic load pulling position:
Cease the pressurized air applied on the coupling over P point.
LOAD PULLING PROCESS
Please follow the following instructions and rules during the pulling process:
➢ Avoid sudden movements during the pulling process and start the operation by slowly
pushing the controlling lever.
➢ Make sure that there is no one present in the operation site.
➢ Do not try to pull loads that exceed the capacity of the Hydraulic winch. Place the vehicle on
a certain line with the Hydraulic winch before starting the pulling process.
Place the vehicle on a certain line with the Hydraulic winch before starting the pulling process.
Where this is not possible, direct the rope towards the load with the help of the pulley and
tackle as can be seen in the drawing.
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LOAD PULLING PROCESS
Fixed Support
As can be seen in the above drawing, you can pull 6000kg of load with a
3000kg of pulling force using the tackle system.
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GENERAL MAINTENANCE
Please read the general maintenance instructions and rules given in this manual for a safe and
longer life-cycle. Otherwise, the Hydraulic winch may be damaged, thus leading accidents.
THE OIL CHANGING PROCESS SHOULD BE DONE ONCE IN CHANGING THE
LUBRICATION OIL
FOR TORAco THW-8K Small, TORAco THW-10K Small, TORAco THW-12K Small, TORAco THW-
15K Large, TORAco THW-16K, TORAco THW-18K Models
➢ First, open the gear box oil filling plug, which is numbered as 1.
➢ Then open the oil discharge plug, which is numbered as 3, and discharge the oil to a
container.
➢ After discharging all the oil, close the oil discharge plug and dismantle the oil level plug,
which is numbered as 2.
➢ Fill up the gearbox oil with a quality SAE-80 until the up to oil level plug, and close down the
plug.
➢ Finish the process by closing the gearbox oil filling plug (plug no.: 1).
THE OIL CHANGING PROCESS SHOULD BE DONE ONCE IN EVERY TWO YEARS!
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PROBLEM – CAUSE – SOLUTION TABLE
PROBLEM CAUSE SOLUTION
• Check the hydraulic oil level.
• Check all the hydraulic fitting
No oil flow rate
and the components against
leakages and congestions.
• Check the pressure on the
brake input. (min. 40bar)
Hydraulic brake does not • Check the brake valve
release. for any contamination. If
contaminated, clean it up.
The Hydraulic winch is • Check the brake hose.
not working.
PTO is not ON • Put the PTO into use.
Damaged hydromotor • Change the hydromotor
Damaged pump • Change the pump
Damaged hydraulic fitting • Change the damaged part
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PROBLEM – CAUSE – SOLUTION TABLE
PROBLEM CAUSE SOLUTION
• Move the pulley back and
Empty-loaded lever does forth using the control valve.
not lock. The locking pin will be
engaged.
Hosting drum (pulley) is
not rotating Damaged return spring
on the empty-loaded • Contact the manufacturer
lever
Damaged gear system • Contact the manufacturer
Damaged or jammed
• Contact the manufacturer
empty-loaded lever shaft
The empty-loaded lever Damaged return spring
of the hoisting rope is not on the empty-loaded • Contact the manufacturer
lever
locked.
• Move the pulley back and
Pin not snapping into the forth using the control valve.
socket The locking pin will be
engaged.
Damaged hydromotor • Contact the manufacturer
Contaminated hydraulic • Clean or change the
oil and filters hydraulic oil and the filters
The Hydraulic winch is Air inside the hydraulic
• Deaerate the system
shaking out during the system
pulling process.
Contaminated control • Clean up the contaminated
valve valve.
Damaged hydraulic brake • Contact the manufacturer
• Increase the oil flow of the
Low oil flow
system.
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POINTS TO CONSIDER WITH REGARDS TO ROPE
The rope in the Hydraulic winch should not be used when damaged due to abrasion and
corrosion. Otherwise, it may lead to serious accidents. The drawing, against which certain
actions are required to be taken, can be seen as follows in this respect.
Under such circumstances, the rope must be replaced with a new one.
Movement of
the rope on
1 the sharp edge 6 Corrosion
under load
Abrasion on the Wire breakage
2 supporting
structure.
7 due to twisting
wear-out
Wearing out
and rupture of Wire breakage
the rope due to on the middle
3 working on a
wide/narrow
8 surface, which
is named as
groove and castle breakage
pulley
Abrasion due Detachment of
to the pressure
4 applied on the 9 the vein due to
applying of high
wires pressure
“Bird Cage”
occurring on
Abrasion due to
untwisted
5 wearing out and
friction
10 ropes due to
unbalanced
twisting
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WARRANTY TERMS
➢ 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 “TORAco ”.
➢ 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, “TORAco” may request the broken parts to be sent. “TORAco” reserves the right
to make changes on the Warranty Terms.
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11417 IL 19, Franklin Park, IL 60131
(630) 785-2410
toracompany
(708) 654-2584
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