HYDRAULIC WINCH

80RVSHY / 80RVSDY / 10RVSHY / 15RVSHY / 18RVSHY

Assembly & Operating Instructions

Introduction

Warrior has developed several new series that make up the current product line. Each series in our product line has unique design characteristics, with many new patented technologies integrated into our winches. The HWP series winch is part of this new product line and features two speeds, a single shaft clutch and speed control, and automatic reducer gear engagement. There are three positions for reducer gear engagement: high gear, low gear, and free spool. This new technology offers peak user convenience and reliability. You will take pride in knowing that your new winch has been designed to work as hard as you do and will be there when you need it.

Congratulations on your purchase of a highest-class, advanced, powerful two-speed winch. Warrior designs and builds winches to strict specifications, and with proper use and maintenance, they should provide years of satisfying service.

WARNING: Read, study, and follow all instructions before operating this device. Failure to heed these instructions may result in personal injury and/or property damage.

Your winch can develop tremendous pulling forces and, if used unsafely or improperly, could result in property damage, serious injury, or death. Throughout this manual, you will find the following symbols for caution, warning, and danger. Pay particular attention to the notes preceded by these symbols, as they are written for your safety. Ultimately, safe operation of this device rests with you, the operator.

CAUTION: This indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This notation is also used to alert you against unsafe practices.

WARNING: This indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Safety Warnings and Precautions

WARNING: When using the tool, basic safety precautions should always be followed to reduce the risk of personal injury and damage to the equipment. Read all instructions before using this tool!

Winch Warnings and Precautions

Unpacking

When unpacking, check to make sure all parts are included. Refer to the Assembly Drawings and Parts List (both with the 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 most popular vehicle and mounting channels. If you cannot find a kit locally, contact Warrior Winches for the name of a dealer near you. If you will utilize a mounting channel, 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 winch will allow even distribution of the full rated load.

2. Mount the winch to the vehicle using high-strength cap screws. It should be aligned and secured to a solid part of the vehicle (front or rear) where the full rated load will be evenly distributed.

3. Please refer to the installation illustrations.

Working Hydraulic Principle Chart and Installation Illustration

The hydraulic system schematic illustrates the flow of hydraulic fluid from the engine-driven pump, through the oil tank, cooler, control valve, and to the hydraulic motor. Key components include the relief valve, selector valve, and control unit, which manage pressure and direction. The system is designed for efficient power transfer to the winch.

Installation Illustration of Winch

This illustration shows the winch unit mounted on a base plate, indicating the use of "Frontal Mounting Plata" and "Back mounting plata" for securing the winch. It details the placement of bolts and washers for a stable installation.

Installation Illustration with Roller Fairlead of Winch

This view depicts the winch installation with the addition of a roller fairlead assembly attached to the front of the winch unit, facilitating smoother cable entry and exit.

Caution

The hydraulic system needs a relief valve to ensure system safety. The absence of such a valve could cause serious injury and damage the winch.

Winch battery cables should be placed so that there is a small amount of slack in the cable. If you are using a heat exchanger with your application to cool the hydraulic fluid, you should refer to the illustration about mounting. You should check the hydraulic fluid level and replace any that may have seeped out. The hydraulic system should be purged at this time. The directions on how to purge the hydraulic system are listed below:

  1. Start the engine.
  2. Power the winch to draw out about 5 feet of cable.
  3. Shut down the engine.
  4. Check the fluid level and fill as needed.
  5. Repeat steps 1 through 4 as necessary.
  6. Start the engine.
  7. Move the cable into the desired position.
  8. Turn the wheels on the vehicle from the right lock to the left lock positions five times to help bleed the hydraulic system.
  9. If the hand control unit is working backwards, simply exchange the brown and the white wire connections within the valve.

Test the winch for proper operation. Refer to the section below.

Operation

WARNING:

  1. Make sure the clutch is totally engaged before starting any winch operation.
  2. Stay clear and away from raised loads.
  3. Stay clear of the cable while pulling; do not try to guide the cable.
  4. Ensure a minimum of 5 wraps of cable around the drum barrel.

General Information

The winch's standard equipment includes a 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 and can be used underwater.

There are several other ways to supply power to the winch. The first way is to use an individual pump for engineering use. The second way is to provide the winch's hydraulic pressure with the vehicle's existing power steering pump (See Installation Instructions).

Caution: Hydraulic systems need a relief valve to ensure the system is safe. If there is no relief valve in the system, it would be a serious danger, and the system cannot operate. If your winch is driven 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 it to the item being pulled.

Caution: Always leave at least five turns of cable on the drum. Review Winch Safety Warnings and Precautions on pages 2 and 3 before continuing.

  1. Reengage the clutch by turning the clutch assembly to the "CLUTCH IN" position as needed.
  2. Test-run the winch in both directions. Turn the winch in each direction for about one or two seconds, ensuring the clutch is totally engaged automatically.
  3. While standing aside of the tow path, hold and operate the switch assembly supplied by your choice. Wait until the motor stops before reversing directions.

Winch Accessories You Will Need (Not Included With Your Winch)

Rigging Techniques

Self-Recovery

Figure 3.1 Description: Illustrates correct and incorrect anchor points for self-recovery. The correct method shows a sling attached to a sturdy anchor point, while the incorrect method shows the clevis hook attached back onto the cable, which can cause damage.

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, as shown in Figure 3.1.

Figure 3.2 Description: Depicts the winch operating from an acute angle. The correct method shows the cable pulling at a 90° angle to the winch/vehicle for long pulls, while the incorrect method shows an acute angle where the wire rope can pile up on one side of the drum, causing damage.

CAUTION: Do not winch from an acute angle, as the wire rope will pile up on one side of the drum, causing damage to the wire rope and the winch. Figure 3.2 shows this scenario. 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.

Figure 3.3 Description: Shows how to protect against cable snap-back during heavy pulls. A blanket or jacket is placed over the wire rope. The illustration also shows opening the vehicle's hood for additional protection.

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 Figure 3.3.

Figure 3.4 Description: Illustrates the use of a snatch block/pulley block for double-lining the wire rope during pulls over 70% of the rated line pull. This method reduces the load on the winch and the strain on the rope.

For pulls over 70% rated line pull, Warrior recommends the use of the snatch block/pulley block to double line the wire rope, as shown in Figure 3.4. This reduces the load on the winch and the strain on the rope by up to 50%, depending on the included angle.

Figure 3.5 Description: A warning symbol indicating that the winch should not be used for overhead hoisting or for lifting or moving people.

WARNING: Never use your winch for overhead hoisting or for lifting people or moving people.

Lubrication

  1. All moving parts within the Winch have been lubricated using high-temperature lithium grease at the factory. No internal lubrication is required.
  2. Lubricate the 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. Turn the clutch to the "CLUTCH OUT" position.
  2. Extend the cable assembly to its full length. Note how the existing cable is connected to the drum.
  3. Remove the old cable assembly and attach the new one as the old cable was connected to the drum. Insert the end of the new rope and secure the screw tightly.
  4. Turn the clutch to the "CLUTCH IN" position.
  5. Retract the cable assembly onto the drum, ensuring the first five wraps are careful not to allow kinking. Then, the winch cable must be wound onto the drum under a load of at least 10% of the rated line pull.

WARNING: Only replace the wire rope with the identical replacement part recommended by the manufacturer.

Trouble Shooting

Symptom Possible Cause Suggested Action
Winch does not turn. - Insufficient hydraulic system pressure.
- Improper connections of hydraulic system, no oil into motor.
- Check relief valve to regulate pressure.
- Check all the plumbing fixtures according to the working principle chart.
- Defective directional control valve.
Motor runs but Cable drum does not turn - The clutch is Not engaged - Turn the clutch to the high or low speed position. If the problem still persists, a qualified technician is needed to check and repair.
Winch drum runs slowly or without normal power. - Insufficient pressure or oil flow
- Insufficient fluid in the system
- Wrong winch working direction.
- Bump is not suitable or defective. Change to a new one or a suitable one.
- Check fluid level. Add fluid until full.
- Change the connection of the balance valve and motor.
Winch cannot spool off wire rope with load smoothly. - Wrong winch working direction. - Change the connection of the balance valve and motor.

Winch Assembly Drawing (80RVSHY/80RVSDY/10RVSHY)

This section contains an exploded view diagram of the winch, showing the arrangement of various components such as the drum, motor, gear housing, clutch assembly, and associated parts. The components are numbered to correspond with the parts list for easy identification during assembly or maintenance.

Winch Parts List (80RVSHY/80RVSDY/10RVSHY)

No. Part # Qty Description Remark
1HV10000011High-pressure oil tube
2HV10000022Oil connection
3HV10000032Combination Washer 14
4HV10000042Cap Screw M12 x 30
5HV10000052Lock Washer Φ12
6HV1000100-11Hydraulic MotorUsed in 80RVSHY 80RVSDY
HV1000100-21Hydraulic MotorUsed in 10RVSHY
7HV10000061Blanced valve
8HV10000074Cap Screw M8 x 55
9HV100000812Lock Washer Φ8
10HV10000098Screw M8 x 30
11HV10000101Brake stents
12HV10000113Brake block
13HV10000122Friction plate
14HV10000132O-ring seal 100*3.55
15HV10000141Piston
16HV10000151O-ring seal 140*2.65
17HV10000162Disk spring
18HV10000172O-ring seal 118*3.55
19HV10000181Motor bracket
20HV10000191Coupling
21HV1000020-11Transmission shaftUsed in 80RVSHY 10RVSHY
HV1000020-21Transmission shaftUsed in 80RVSDY
22HV10000212Bearing bush
23HV10000222Ring Seals
24HV10000238Screw M10 x 25
25HV100002416Lock Washer Φ10
26HV1000025-11Stand bar (b)Used in 80RVSHY 10RVSHY
HV1000025-21Stand bar (b)Used in 80RVSDY
27HV1000026-11Stand bar (a)Used in 80RVSHY 10RVSHY
HV1000026-21Stand bar (a)Used in 80RVSDY
28HV10000272Screw M8 x 15
29HV1000200-11Drum AssemblyUsed in 80RVSHY 10RVSHY
HV1000200-21Drum AssemblyUsed in 80RVSDY
30HV10000281Coupling I
31HV100002916Cap Screw M6 x 20
32HV100003016Lock Washer Φ6
33HV10000311End Bearing
34HV10003001Gear Carrier Assembly (Output)
35HV10000322Gasket
36HV10000331Gear-Ring (Output)
37HV10004001Gear Carrier Assembly (Input)
38HV10000341Circlip for hole Φ125
39HV10000351Gear-Ring (Input)
40HV10000361Gear-Input Sun
41HV10000371Trust Washer
42HV10000381Axle sleeve
43HV10000391Cover-Gear Housing
44HV10005001Clutch Assembly
45HV10000408Screw M10 x 35
46HV10000418Think Flat Washer Φ10
47HV1000600-11Roller FairleadUsed in 80RVSHY 10RVSHY
HV1000600-21Roller FairleadUsed in 80RVSDY
48HV1000700-11Cable AssemblyUsed in 80RVSHY 80RVSDY
HV1000700-21Cable AssemblyUsed in 10RVSHY
49HV1000800-11Tensioned Of Steel Wire Supplied AssemblyUsed in 80RVSHY 10RVSHY
HV1000800-21Tensioned Of Steel Wire Supplied AssemblyUsed in 80RVSDY

Outline Dimensional Drawing

This section provides dimensional drawings for the Warrior winch models. Key dimensions are listed in both inches and millimeters for the following models:

80RVSHY

Overall dimensions: 23.23" x 9.3" x 9.5" (590mm x 237mm x 241mm). Mounting bolt pattern: 10" x 4.5" (254mm x 114.3mm) and 10" x 6.5" (254mm x 165.1mm) 8-M10. Drum size: Ø4.0" x 7.91" (Ø102mm x 201mm).

80RVSDY

Overall dimensions: 22.0" x 9.3" x 9.5" (558mm x 237mm x 241mm). Mounting bolt pattern: 8.74" x 4.5" (222mm x 114.3mm) and 8.74" x 6.5" (222mm x 165.1mm) 8-M10. Drum size: Ø4.0" x 6.65" (Ø102mm x 169mm).

10RVSHY

Overall dimensions: 23.4" x 9.3" x 9.5" (594mm x 237mm x 241mm). Mounting bolt pattern: 10" x 4.5" (254mm x 114.3mm) and 10" x 6.5" (254mm x 165.1mm) 8-M10. Drum size: Ø4.0" x 7.91" (Ø102mm x 201mm).

Winch Assembly Drawing (15RVSHY/18RVSHY)

This section contains an exploded view diagram of the winch, showing the arrangement of various components such as the drum, motor, gear housing, clutch assembly, and associated parts. The components are numbered to correspond with the parts list for easy identification during assembly or maintenance.

Winch Parts List (15RVSHY/18RVSHY)

No. Part # Qty Description Remark
1HV15000011High-pressure oil tube
2HV15000022Oil connection Oil
3HV15000032Combination Washer 14
4HV15000042Cap Screw M12 x 30
5HV15000052Lock Washer Φ12
6HV1500100-11Hydraulic MotorUsed in 15RVSHY
HV1500100-21Hydraulic MotorUsed in 18RVSHY
7HV15000061Blanced valve
8HV15000074Cap Screw M8 x 55
9HV150000836Lock Washer Φ8
10HV15000098Screw M8 x 30
11HV15000101Brake stents
12HV15000113Brake block
13HV15000122Friction plate
14HV15000132O-ring seal 100*3.55
15HV15000141Piston
16HV15000151O-ring seal 140*2.65
17HV15000162Disk spring
18HV15000172O-ring seal 118*3.55
19HV15000181Motor mounting plate
20HV15000193Gasket
21HV15000201Motor bracket
22HV150002124Screw M8 x 25
23HV15000221Coupling
24HV15000231Transmission shaft
25HV15000242Bearing bush
26HV15000252Ring Seals
27HV15000268Screw M10 x 25
28HV150002716Lock Washer Φ10
29HV15000281Stand bar(a)
30HV15000291Stand bar(b)
31HV15000302Screw M8 x 15
32HV1500200-11Drum AssemblyUsed in 15RVSHY
HV1500200-21Drum AssemblyUsed in 18RVSHY
33HV15000311Coupling I
34HV15000321End Bearing
35HV15003001Gear Carrier Assembly (Output)
36HV15000331Gear-Ring (Output)
37HV15004001Gear Carrier Assembly (Input)
38HV15000341Circlip for hole Φ125
39HV15000351Gear-Ring (Input)
40HV15000361Gear-Input Sun
41HV15000371Trust Washer
42HV15000381Axle sleeve
43HV15000391Cover-Gear Housing
44HV15005001Clutch Assembly
45HV15000408Screw M10 x 35
46HV15000418Think Flat Washer Φ10
47HV15006001Roller FairleadUsed in 15RVSHY
48HV1500700-11Cable AssemblyUsed in 15RVSHY
HV1500700-21Cable AssemblyUsed in 18RVSHY
49HV15008001Tensioned Of Steel Wire Supplied Assembly

Outline Dimensional Drawing

This section provides dimensional drawings for the Warrior winch models. Key dimensions are listed in both inches and millimeters for the following models:

15RVSHY

Overall dimensions: 28.9" x 11.8" x 10.9" (735mm x 300mm x 277mm). Mounting bolt pattern: 12.0" x 4.5" (303.5mm x 114.3mm) and 14.5" x 6.7" (368.5mm x 171.2mm) 8-M12. Drum size: Ø5.0" x 10.5" (Ø127mm x 266mm).

18RVSHY

Overall dimensions: 29.2" x 11.8" x 10.9" (742mm x 300mm x 277mm). Mounting bolt pattern: 12.0" x 4.5" (303.5mm x 114.3mm) and 14.5" x 6.7" (368.5mm x 171.2mm) 8-M12. Drum size: Ø5.0" x 10.5" (Ø127mm x 266mm).

Specification (80RVSHY)

ParameterValue
Rated line pull8000 lbs (3629 kgs)
Motor displacement80ml/r
Oil flow5~60L/min
Pressure12Mpa
Gear reduction ratio17.6:1
Cable (Dia. × L)Ø3/8"×98.4' (Ø9.2mm×30.0m)
Drum size(Dia. × L)Ø4.0"×7.91" (Ø102mm×201mm)
Mounting bolt pattern10"×4.5" (254mm×114.3mm) ; 10"×6.5" (254mm×165.1mm) 8-M10
Overall dimensions (L×W×H)23.23"×9.3"×9.5" (590mm ×237mm ×241mm)
Net weight lbs(kg)108 (49)

Pull, Speed, Pressure, Flow (First layer)

Line pull lbs (kgs)Pressure Mpa(Psi)Flow G/min (L/min)Line speed ft/min(m/min)
02.0(290.1)1.3(5)3.2(1.0)
4000(1814)5.0(725.2)5.3(20)10.8(3.3)
6000(2722)8.0(1160.3)10.5(40)23.9(7.3)
8000(3629)12.0(1740.4)15.8(60)37.7(11.5)

Line Pull And Rope Capacity Inlayer

Layer of wire ropeRated line pull lbs(kgs)Total rope on drum ft (m)
18000(3629)21.3(6.5)
26864(3113)49.2(15.0)
36010(2726)80.4(24.5)
45345(2424)98.4(30.0)

Specification (80RVSDY)

ParameterValue
Rated line pull8000 lbs (3629 kgs)
Motor displacement80ml/r
Oil flow5~60L/min
Pressure12Mpa
Gear reduction ratio17.6:1
Cable (Dia. × L)Ø3/8"×98.4' (Ø9.2mm×30.0m)
Drum size(Dia. × L)Ø4.0"×6.65" (Ø102mm×169mm)
Mounting bolt pattern8.74"×4.5" (222mm×114.3mm) ; 8.74"×6.5" (222mm×165.1mm) 8-M10
Overall dimensions (L×W×H)22.0"×9.3"×9.5" (558mm ×237mm ×241mm)
Net weight lbs(kg)105 (47.6)

Pull, Speed, Pressure, Flow (First layer)

Line pull lbs (kgs)Pressure Mpa(Psi)Flow G/min (L/min)Line speed ft/min(m/min)
02.0(290.1)1.3(5)3.2(1.0)
4000(1814)5.0(725.2)5.3(20)10.8(3.3)
6000(2722)8.0(1160.3)10.5(40)23.9(7.3)
8000(3629)12.0(1740.4)15.8(60)37.7(11.5)

Line Pull And Rope Capacity Inlayer

Layer of wire ropeRated line pull lbs(kgs)Total rope on drum ft (m)
18000(3629)18.4(5.6)
26864(3113)42.3(12.9)
36010(2726)69.5(21.2)
45345(2424)98.4(30.0)

Specification (10RVSHY)

ParameterValue
Rated line pull10000 lbs (4536 kgs)
Motor displacement100ml/r
Oil flow5~60L/min
Pressure15Mpa
Gear reduction ratio17.6:1
Cable (Dia. × L)Ø13/32"×98.4' (Ø10.2mm×30.0m)
Drum size(Dia. × L)Ø4.0"×7.91" (Ø102mm×201mm)
Mounting bolt pattern10"×4.5" (254mm×114.3mm) ; 10"×6.5" (254mm×165.1mm) 8-M10
Overall dimensions (L×W×H)23.4"×9.3"×9.5" (594mm ×237mm ×241mm)
Net weight lbs(kg)110 (49.9)

Pull, Speed, Pressure, Flow (First layer)

Line pull lbs (kgs)Pressure Mpa(Psi)Flow G/min (L/min)Line speed ft/min(m/min)
03.0(435.1)1.3(5)3.0(0.9)
4000(1814)6.8(986.2)2.6(10)5.9(1.8)
6000(2722)9.2(1334.3)5.2(20)11.8 (3.6)
8000(3629)12.0(1740.4)10.4(40)23.6(7.2)
10000(4536)15.0(2175)15.6(60)36.1(11)

Line Pull And Rope Capacity Inlayer

Layer of wire ropeRated line pull lbs(kgs)Total rope on drum ft (m)
110000(4536)23.0(7.0)
27355(3336)49.2(15.0)
36780(3075)78.7(24.0)
45711(2591)98.4(30.0)

Specification (15RVSHY)

ParameterValue
Rated line pull15000 lbs (6804 kgs)
Motor displacement160ml/r
Oil flow5~60L/min
Pressure17.5Mpa
Gear reduction ratio17.3:1
Cable (Dia. × L)Ø15/32"×98.4' (Ø12mm×30.0m)
Drum size(Dia. × L)Ø5.0"×10.5" (Ø127mm×266mm)
Mounting bolt pattern12.0"×4.5" (303.5mm×114.3mm); 14.5"×6.7" (368.5mm×171.2mm) 8-M12
Overall dimensions (L×W×H)28.9"×11.8"×10.9" (735mm ×300mm ×277mm)
Net weight lbs(kg)184.3 (83.6)

Pull, Speed, Pressure, Flow (First layer)

Line pull lbs (kgs)Pressure Mpa(Psi)Flow G/min (L/min)Line speed ft/min(m/min)
02.0(290)2.6(10)4.2(1.3)
8000(3629)9.2(1337)5.2(20)8.5(2.6)
10000(4536)11.5(1627)7.9(30)12.4 (3.8)
12000(5448)14.0(2030)10.4(40)16.7(5.1)
15000(6810)17.5(2537)15.6(60)23(7)

Line Pull And Rope Capacity Inlayer

Layer of wire ropeRated line pull lbs(kgs)Total rope on drum ft (m)
115000(6804)29.5(9.0)
212791(5807)65.6(20.0)
311150(5062)98.4(30.0)

Specification (18RVSHY)

ParameterValue
Rated line pull18000 lbs (8165 kgs)
Motor displacement200ml/r
Oil flow5~60L/min
Pressure16Mpa
Gear reduction ratio17.3:1
Cable (Dia. × L)Ø9/16"×91.8' (Ø14mm×28.0m)
Drum size(Dia. × L)Ø5.0"×10.5" (Ø127mm×266mm)
Mounting bolt pattern12.0"×4.5" (303.5mm×114.3mm); 14.5"×6.7" (368.5mm×171.2mm) 8-M12
Overall dimensions (L×W×H)29.2"×11.8"×10.9" (742mm ×300mm ×277mm)
Net weight lbs(kg)190 (86.2)

Pull, Speed, Pressure, Flow (First layer)

Line pull lbs (kgs)Pressure Mpa(Psi)Flow G/min (L/min)Line speed ft/min(m/min)
02.0(290.1)2.6(10)4.6(1.4)
8000(3629)5.8(841.2)5.2(20)6.6(2.0)
12000(5448)9.2(1334.3)10.4(40)13.1(4.0)
15000(6810)12.0(1740.5)13.2(50)17.4(5.3)
18000(8165)16.0(2320.6)15.6(60)24(7.3)

Line Pull And Rope Capacity Inlayer

Layer of wire ropeRated line pull lbs(kgs)Total rope on drum ft (m)
118000(8165)25.9(7.9)
215017(6811)58.7(17.9)
312882(5843)91.8(28.0)
Models: Hydraulic Winch, 80RVSHY, 80RVSDY, 10RVSHY, 15RVSHY, 18RVSHY

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