ELECTRIC SYNTHETIC WINCHManual and Safety Instructions

MODELS:M10000S and M12500S

PLEASE READ CAREFULLY BEFORE OPERATING THE WINCH

CONTENT

1. Package Contents ________________________________________________________________________ 01

2. Safety Warnings & Precautions _________________________________________________________ 01 - 04 3. Electric Winch Installation _____________________________________________________________ 04 - 06 4. Electric Winch Operation ______________________________________________________________ 07 - 11 5. Electric Winch Maintenance and Storage _________________________________________________ 11 - 12 6. Troubleshooting Guide ____________________________________________________________________ 12

7. Winch Diagram View and Parts List _________________________________________________________ 13

8. Specifications ___________________________________________________________________________ 14

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1. Package Contents 1. Winch 2. Winch Control Box 3. Ground Wire 4. Wireless Remote Controller 5. Wired Remote Controller 6. Wire Connector 7. Hawse Fairlead 8. Clevis Hook (Including Lanyard) 9. Mounting Screw Bolts

2. Safety Warnings & Precautions

•Vehiclebatteriescontaingasesthatareflammableandcanexplodeviolently Dress properly

•Donotwearlooseclothingorjewelry.Theycanbecaughtinmovingparts •Non-skidfootwearisrecommended •Protectivehaircoveringortiebacklonghair

Battery •Alwayscheckandensureyourbatteryisingoodcondition.Avoidcontactwithbatteryacidorothercontaminants •Alwaysweareyeprotectionwhenworkingaroundabattery •Alwaysfollowwiringdiagrams •Toavoidflatteningthebatteryhavetheenginerunningwhenusingthewinch

•Improperwiringcanresultinelectricalshockorexplosion •Alwaysinsulateandprotectallexposedwiringandelectricalterminals •Alwaysplacesuppliedterminalbootsonwiresandterminalsasdirectedbyinstallationinstructions •NeverconnectDCPoweredwinchestoACcurrent •NeveroperateaDCwinchinthepresenceofflammablesorfumes •Neverrouteelectricalcablesacrosssharpedges;nearpartsthatgethot,northroughoraroundmovingparts •Alwaysverifytheareaisclearoffuellines,fueltanks,brakelines,electricalwires,etc.,whendrilling •Alwaysconsulttheoperator’smanualforproperwiringdetails

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•Improperuseoroverloadingofthewinchcanresultinareleaseofloadorropefailure Before winching a load, be sure the clutch is fully in the engaged position • Always properlyseatloadinhook • Alwaysuseashackleorstrapwhenattachingthehooktoananchorpoint • Always useahookwithalatchandinsurehooklatchisclosedandnotsupportingload • Always keephandsclearoftherope,hookloop,hookandfairleadopeningduringinstallation,operation andwhenspoolinginorout • Always usethesuppliedhookstrapwheneverspoolingropeinoroutduringinstallationandoperation • Never touchropeorhookwhileintensionorunderload • Neverhooktheropebackontoitself • Never usethewinchtoliftormovepersons • Never usethewinchasahoistortosuspendaload

Moving Parts Entanglement Hazard •Keepthedurationofyourpullsasshortaspossible •Donotstepoverthesyntheticrope,orneartheropewhenitisunderload • Never engageordisengagetheclutchifthewinchisunderload,theropeisintensionorthedrumismoving • Always keephandsclearoftherope,hookloop,hookandhawsefairleadopeningduringinstallation,operation orwhenspoolinginorout • Always keepthewiredremotecontrolleadclearofthedrum,ropeandrigging.Inspectforcracks,pinches, frayedwiresorlooseconnections.Replaceremotecontrolifdamaged • Always passthewiredremotecontrolthroughawindowtoavoidpinchingtheleadinthedoor,whenusing remoteinsideavehicle • Never leavetheremotecontrolwhereitcanbeactivatedduringfreespooling,rigging,orwhenthewinch isnotbeingused •Ifthemotorbecomesuncomfortablyhottothetouch,stopandletitcoolforafewminutes.Donotpullmorethan oneminuteatorneartheratedload.Donotmaintainpowertothewinchifthemotorstalls

General Safety

• Always knowyourwinch.TakethetimetofullyreadtheInstallationGuideandtheBasicGuidetoWinchingTechniques inordertounderstandyourwinchanditsoperation •Electricwinchesareforintermittentusageandshouldnotbeusedinconstantdutyapplications •Modificationoralterationtothewinchshouldonlybemadebyqualifiedpersonnelandmayvoidwarranty • Never operatethewinchifyouareunder16yearsofage • Never operatethewinchwhenundertheinfluenceofdrugs,alcoholormedication • Never exceedthewinchorropecapacitylistedonproductdatasheet.Toreducewinchloaduseadoubleline andsnatchblock •Alwaysbeawareofyourvehiclesstabilityofvehicleandloadduringwinching.Alertallbystandersofan unstableconditionifitarises •Keepa safe distance,properfootingandbalanceatalltimes

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Installation Safety • Always inspectrope,hook,andslingsbeforeoperatingwinch.Frayed,kinkedordamagedropemustbereplaced immediately.Damagedcomponentsmustbereplacedbeforeoperation.Ifacablepullslooseorbreaksunderload itcanlashbackandcauseseriespersonalinjuryordeath

(Figure2-1)

• Always pre-stretchtheropeandre-spoolunderloadbeforeuse.Tightlywoundropereducesthechances of“binding”,whichcandamagetherope • Always spooltheropeontothedruminthedirectionspecifiedbythewinchwarninglabelonthewinch and/ordocumentation.Thisisrequiredfortheautomaticbrake(ifsoequipped)tofunctionproperly • Always chooseamountinglocationthatissufficientlystrongenoughtowithstandthemaximumpullingcapacity ofyourwinch • Always usefactoryapprovedmountinghardware,components,andaccessories • Always usegrade5(grade8.8metric)orbettermountinghardware • Never weldmountingbolts • Always usecautionwhenusinglongerboltsthanthosesuppliedfromfactory.Boltsthataretoolongcandamage thebaseand/orpreventthewinchfrombeingmountedsecurely • Always mountthewinchandattachthehooktotherope’sendloopbeforeconnectingtheelectricalwiring • Always positionfairleadwithWARNINGlabelontop • Neverobscurethewarningandinstructionlabels.Slowlytakeuptheropeslackuntiltaut • Never leavetheremotecontrolpluggedintowinchwhenfreespooling,rigging,orwhenthewinchis notbeingused • Always useachokerchain,chokerrope,ortreetrunkprotectorontheanchor • Always becertainthattheanchoryouselectwillwithstandtheloadandthestraporchainwillnotslip • Always selectananchorpointasfarawayaspossible.Thiswillprovidethewinchwithitsgreatestpullingpower • Neveroperatethewinchwithlessthan8turnsofsyntheticropearoundthewinchdrum.Theropecould comeloosefromthedrum • Neverexposetheropetoheatsourcesorchemicals • Neverpulltheropearoundnon-rotatingsheavesorrollers • Neverallowtheropetotangleorjamwhilewinching.Theropecouldbreakbeforethewinchstalls • Neverknotortietheropetosecurealoadorrepairabrokenrope • Neveruseahookwhosethroatopeninghasincreased,orwhosetipisbentortwisted • Never usetoraise,suspend,lowerorsecurehorizontallyhingeddoorsorrampswithoutadditionalcounterbalance springs,centrifugallockingdevices,orothersecondarymeansofsupportingthemovingrampordoor • Alwaysstoretheremotecontrolinaprotected,clean,dryarea • Alwaysdoublelineorpickadistantanchorpointwhenrigging.Thismaximizespullingpowerandavoidsoverloading •Placerecoveryblanketonropeifpossiblebeforeoperatingwinch,itwillmakevehicleandoperatorsaferiftherope shouldbecomedamaged

Avoid Winch and Equipment Damage • Always avoidsidepullswhichcanpileuptheropeononeendofthedrum.Thiscandamagetheropeorwinch

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•Winchingshouldalwaysbedoneinastraightlinefromthewinchtotheobjectbeingwinched.Thisprevents thewinchfrombeingdamaged •Do not operatethewinchatextremeangles.Thehawsefairleadangleshouldbeasclosetostraightaspossible • Never useawinchtotowothervehiclesorobjects.Shockloadscanmomentarilyexceedthecapacityofrope andwinch • Always avoid“poweringout”forextendeddistances.Thiscausesexcessheatandwearonthewinchmotor/brake • Always usecaretonotdamagethevehicleframewhenanchoringtoavehicleduringawinchingoperation • Never “jog”ropeunderload.Shockloadscanmomentarilyexceedthecapacityoftheropeandwinch • Never usethewinchtosecurealoadduringtransport • Never submergethewinchinwater • Always storethewiredandwirelessremotecontrolsinaprotected,clean,dryarea

GENERAL TIPS FOR SAFE OPERATION •Topreventbatterydrainandmaximizepowerandspeedofthewinch,thevehicleengineshouldbekeptrunning duringoperation.Ifthewinchisusedforaconsiderableamountoftimewiththeengineoff,thebatterymaydrain andbetooweaktorestarttheengine •Inspectthewinchinstallation,checkboltstoensurethatallboltsaretightenedbeforeeachoperation •Anywinchthatappearstobedamagedinanyway,isfoundtobeworn,oroperatesabnormallySHOULDBE REMOVEDFROMSERVICEUNTILREPAIRED.Itisrecommendedthatthenecessaryrepairsbemadebya manufacturer’sauthorizedrepairfacility •Theropemaybreakbeforethemotorstalls,forheavyloadsatornearratedcapacity,useapulleyblock/snatch blocktoreducetheloadontherope •Donotmovethevehicletopullaload(Towing)onthewinchrope,thiscouldresultinropebreakage •Rewindtheropeontothedrumunderaloadof500lbs(230kg)ormore

3. Electric Winch Installation Unpack Your Winch Unpackyournewwinchandensurethatallofthepartsareincluded.RefertothePartsListandDiagram ViewDrawingprovidedinthismanual.Ifyoufindanypartsmissingorbroken,pleasecontactthestore youpurchasedthewinchfromassoonaspossible.

Mount Your Winch Chooseasuitablelocationtomountthewinchthatisstrongenoughtowithstandtheloads(Amountingplateis recommendedforwinchinstallation).Checkthatyourmountingplateorbumperhassuitablescrewholes,ifnotdrill fourmountingholesaccordingtotheboltpatternmentionedinthewinchspecifications.(SeeFigure3-1)

(Figure3-1) (Picturesaboveforreferenceonly) Attach Your Winch Installyourwinchonthemountingplateorbumper,usingsuppliedfastenersandtighten.

Install Your Winch Fairlead Fixthefairleadonthemountingplateorbumper.Ifyouuseanyothermountingplatforms,drilltwoholesforthe fairleadinstallation.Positiontheholessuchthatthefairleadopeningholestretchesfromthecircumferenceofthe drumtotheendofthemaximumpermissiblelayersonthedruminthedirectioncableisbeing.Notethewinch directionafterinstallation,theroperunsthroughthebottomofthedrum.(SeeFigure3-2)

The rope runs through the bottom of the drum.

(Figure3-2)(Picturesaboveforreferenceonly)

Control Box Assembly Installation Thecontrolboxcanbemountedtothecenterofthewinchorseparatelyfromthewinch.(SeeFigure3-3)

(Figure3-3)

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Connect Electric Cables RoutetheCablesfromthecontrolboxtothebatteryandfromthecontrolboxtotheWinch,following theprecautionsdiscussedabove.(SeeFigure3-4)

(Figure3-4)

Shortredcableconnectstotheredterminal(A)ofthemotor. Shortblackcablewithyellowjacketconnectstotheyellowterminal(F-1)ofthemotor. Shortblackcablewithblackjacketconnectstotheblackterminal(F-2)ofthemotor. Thinblackcableconnectstothegroundterminalofthemotor. Longblackcableconnectstothegroundterminalofthemotor. Long RedcableconnectstothePositive (+)ofbattery. Long BlackcableconnectstotheNegative (-)ofbattery.

Test Your WinchAfterproperinstallationandconnection,placetheclutchinthe“Disengaged”position,pulloutthewinchropeto6.5feetandturntheclutchtothe“Engaged”position.Usetheremotecontroltotestifthewinchworksproperly.Ifthewinchdoesn’twork,pleasecheckifallthethingsareinpropercondition,suchas,ifthecableconnectioniscorrectandtightorthevehiclebatteryissufficient.Ifthewinchstilldoesnotworkafterathoroughcheck,pleasecontactthesupplier.(SeeFigure3-5)

(Figure3-5)

Practice Using Afterthewinchhasbeeninstalled,takesometimeandpracticeusingitsoyouwillbefamiliarwithallofits operations.Periodicallycheckthewinchinstallationtoensurethatalloftheboltsaretight.

Control Box

F-2F-1

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4. Electric Winch Operation

NOTE:Foroptimalwinchperformance,itisrecommendedthatyouuseafullycharged12Vbatterywithatleast650CCA.Itisadvisedtokeeptheenginerunningduringthewinchoperation,sothatthebatteryisbeingchargedcontinuously.All winchesareequippedwithaclutchleverthatengages/disengagestheclutch.Clutchwhenengaged,winchcanpullropein;Clutchwhendisengaged,winchcanpullropeout.

CAUTION:Whenusingyourwinch,alwayshaveatleast8turnsofsyntheticropeonthedrumbeforewinching,Ensuretheclutchisfullyengagedorfullydisengagedtoavoidanyinjuriesordamages.

CAUTION: All Winches are for intermittent use only.Waituntilthemotorcoolsdownbeforeresumingoperation.Potential causes of motor damage:• Long–duration pulls. • Low battery. • Overloading winch pulling capacity. • If there is a large rock right in front of your axle, frame, or skid plate, you can winch horizontally and the only thing you'll accomplish is bending something, or burning out your winch motor.

Step 1: Disengage the Clutch DisengageyourwinchbyliftingandturningtheclutchtotheFREE-SPOOLposition.(SeeFigure4-1)

(Figure4-1)(Picturesaboveforreferenceonly)

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Step 2: Pull Rope to Anchor Point SlidetheloopoftheHookStrapoverthehook,thenpullontheHookStraptopulloutthesyntheticrope.Pullout enoughropetoreachyouranchorpoint.Besuretokeepacertainamountoftensionintherope.Itcanbecome twistedandoverwrapwhenslackened,leadingtoropedamage.Forsafety,alwaysholdthehookstrapwhenhandling thewinchline.(SeeFigure4-2)

(Figure4-2)

Leaveatleast8fullturnsofsyntheticwireropeonthedrum.

Step 3: Engage the Clutch EngageyourwinchbyliftingandturningtheclutchtotheENGAGED position(SeeFigure4-3)

(Figure4-3)(Picturesaboveforreferenceonly)

Ifnecessary,pulltheropeoutslightlyuntiltheclutchisseatedcorrectly.

Step 4: Attach the Wired Controller Attachthewiredcontrollertothesocketonthecontrolbox.(SeeFigure4-4)

(Figure4-4)Step 5: Winching Testthewiredcontrollertoensureitworks.(SeeFigure4-5)Keepasafedistancefromwinchandrope,presstheIN buttontobeginwinching.Ifyouareusingthewirelessremotecontrol,pressINbuttontobeginwinching.

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(Figure4-5)(Picturesaboveforreferenceonly)

Alwaysdisconnecttheremotecontrolwhennotinuse.

Step 6: For Vehicle Recovery Continuepullingthevehicleuntilitisonstableground.Ifyouareabletodrivethevehicle,thewinchingoperation iscomplete.Oncerecoveryofthevehicleiscomplete,besuretosecurethevehicle’sbrakesandputtheTransmission in“park”.Releasethetensionintherope. Disconnecttheropefromtheanchor,andthenrewindtherope.Thepersonhandlingtheropeshouldwalktherope inandnotletitslidethroughthehands.Controlthewinchatalltimes.

Step 7: Disconnect Remote Control Disconnecttheremotecontrolcordandstoreitinacleananddryplace.Winchingoperationsarenowcomplete. Putthecaponthesocket.

• Alwaysbeawareofyourvehiclesstabilityandloadduringwinching.Alertallbystandersofanunstablecondition ifitarises. • Alwayskeepa safe distance,properfootingandbalanceatalltimes. • Alwaysdisconnectthecabletothevehiclebatteryafterwinching. •Besurethecablesarenotdrawntaughtacrossanysurface,whichcouldpossiblydamagethem. •Connecttothebatteryandscrewthenutontoallterminalstoavoidanyconnectionloss. •Usethewiredorwirelessremotecontrollers,afterinstallation,tomakethewinchworkinbothdirections. •Neverhooktheropebackontoitself.Thiscoulddamagetherope.Atreesaverisrecommended.(SeeFigure4-6)

Figure4-6

•Neverallowtheropetotangleorjamwhilewinching.Theropecouldbreakbeforethewinchstalls •Neverexceedthewinchorropecapacitylistedonproductdatasheet.Toreducewinchload,useadoubleline andsnatchblock •Donotreversetheoperationimmediately,waitfordrumtostop.Relaycanbeeasilydamagedinthisway •Avoidcontinuouspullsfromextremeangles.Theangleshouldbeasclosetostraightaspossibleforahawse fairlead.(SeeFigure4-7)

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Figure4-7

Winch Accessories You May Need During Winching Inordertobepreparedforallrecoveryscenariositisrecommendedtobeequippedwithafullrecoverykit orwinchaccessories.

•WinchMountingPlate•FarmJack•Receiver•Shackle•SquareHook •Heavydutychain•TreeSaver•RecoveryBlanket•SnatchBlock•Gloves

Some Tips for Better Winching •Theuseofasnatchblock •DoubleLine Theuseofasnatchblockwillaidrecoveryoperationsbyprovidingadoublingofthewinchcapacityandahalving ofthewinchingspeed,andthemeanstomaintainadirectlinepulltothecenteroftherollers.Whendoubleloading duringstationarywinching,thewinchhookshouldbeattachedtothechassisofthevehicle.(SeeFigure4-8)

Figure4-8

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•ChangethePullingDirection.(SeeFigure4-9)

Figure4-9 •Increasingpullingpowerandduration Forloadsover1/2ratedcapacity,useapulleyblocktodoublelinetherope.Thiswillreducetheloadonthewinch andupto50%ofthestrainontherope.Attachtotheframeorotherloadbearingpart. •GroundAnchor Pulloutthewinchropeandfixtotheanchorpoint.Theanchorpointshouldbeagroundanchororatree strongenoughtorecoverthevehicle.(SeeFigure4-10)

Figure4-10 •Recoveryblanketorotherheavydutymaterial

Thequickestandeasiestwaytopulltheropeoutfromthedrumistofreespoolitwiththeclutchinthedisengaged position.Whenpulling,putadamper,blanketorotherheavydutymaterialovertheropenearthehookend.Ifthe ropefailsforanyreason,therewillbeabarriertohelppreventtheropefromcausinginjury.(SeeFigure4-11)

Figure4-116. Electric Winch Maintenance and Storage General Inspection •Thegearboxhasbeenlubricatedandissealedatthefactory.Nofurtherinternallubricationisrequiredforthelife ofthewinch •Winchesshouldnotbesubmergedinwaterforalongtime •Donotattempttodisassemblethegearbox.Repairsshouldbedonebyanauthorizedrepaircenter •Replacetheropeorcablesassoonaspossibleiftheybecomedamaged.

•Periodicallycheckthetightnessofthemountingboltsandelectricalconnections.Removealldirtorcorrosion andalwayskeepclean.(Checkbatterycablesandelectricalconnectionsat90dayintervalstobecertain theyarecleanandtightatallconnectionpoints.) •Checktheactionoftheclutch.Makesureitfullyengagesanddisengages.Iftheclutchisnotfully engaging,inspecttheclutchshifterassemblyparts.Checkfordamageorexcessivewearandreplaceasnecessary. Corrosionontheelectricalconnectionswillreduceperformanceandmaycauseashort.Cleanallofthe connections,especiallyintheremotecontrolswitchandreceptacle.Insaltyenvironmentsuseasiliconesealerto protectfromcorrosion.

6. Troubleshooting Guide

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SYMPTOM POSSIBLE CAUSE SUGGESTED REMEDY Motor does not turn on Defective switch assembly Replace switch assembly Switchassemblynotconnectedproperly Insertswitchassemblyfirmlytotheconnector Loose battery cable Tighten nuts on cable connectors

Long period of operation Let winch cool down periodically Motor runs too hot Insufficientbattery Checkbatteryterminalvoltageunderload.If10V or less, replace or parallel another battery to it. Battery discharged Recharge battery by running vehicle’s engine Motorrunsslowlyor Insufficientcurrentorvoltage Clean,tightenorreplacetheconnector under powered Bad connection Check battery cable for corrosion. Clean and grease.

Motor runs but cable drum does not turn Clutch not engaged Ensure lever is completely in “Engaged” position Defective or stuck solenoid Tap solenoid to free contacts. Winch runs in one Repair or replace solenoid. direction only Defective switch assembly Replace switch assembly

Disconnect from battery Remove ground bolt on bottom of motor and drain. Motor water damage Submerged in water or water from Allow to drain and dry thoroughly, high pressure car wash then run motor without a load in short bursts to dry windings.

Excessive load Reduce load or double line Will not hold load Worn or damaged brake Repair or replace brake

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7. Winch Diagram

ITEM DESCRIPTION QTY

1 ScrewM5*20 16

2 Gear Box 1

3 Clutch Handle 1

4 Gasket 1

5 Washer 1

6 Needle Bearing 1

7 Sun Gear 1

8 Ring Gear 1

9 Carrier Assembly, (Stage 1) 1

10 Carrier Assembly, (Stage 2) 1

11 Carrier Assembly, (Stage 3) 1

12 Washer 1

13 Ring Gear 1

14 Drum Support, Gear Box 1

15 Drum Bushing 2

16 Seal Kit 2

17 Anti-friction Gasket 8

18 Hex Shaft 1

19 Integrated Tie Bar 1

20 ScrewM8*20 4

21 Drum Assembly 1

22 Brake Assembly 1

23 Connector 1

24 Drum Support, Motor 1

25 Motor 1

26 Gasket 1

27 Motor Assembly Cover 1

28 ScrewM6*10 1

29 Wire Rope Terminal Kit 1

30 Synthetic Rope 1

31 Aluminum Hawse Fairlead 132 Clevis Hook 133 Control Box Assembly 1

34 Screw M6*16 2

35 Battery Lead (Negative) 1

36 Wire Connector 1

37 Wireless Remote Control 1

Winch Part List

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8. Specifications

M12500S WINCHRatedLinePull 12,500LBsSinglelineMotor Serieswound6.6HP/4.9KW,12VDCGear Train 3 Stage planetaryGear Ratio 216 : 1Clutch Sliding ring gearBraking Action: Automatic in the drumFairlead Aluminum hawse fairleadSynthetic Rope 7/16” x 85’ Drum Size 2.5” x 9”Dimensions 22.17” x 6.38” x 7.72”BoltPattern 10”x4.5”N.W. 66LBs

Line Pull:

Line Speed:

Motor Current:

LbsKgs

FPMMPM

Amps

LINE SPEED & MOTOR CURRENT(FIRST LAYER)

0 4000 6000 9500 125000 1814 2722 4309 5670

32.8 15.1 13.1 10.5 9.210 4.6 4 3.2 2.870 210 260 380 420

M

Layer of Cable

Rated Line Pull Per Layer

Cable Capacity Per Layer:

LbsKgsFt

LINE PULL & CABLE CAPACITY1 2 3 4

12500 9919 8220 70195670 4499 3729 318315.75 35.5 59.4 854.8 10.8 18.1 26

M10000S WINCHRatedLinePull 10,000LBsSinglelineMotor Serieswound6.0HP/4.8KW,12VDCGear Train 3 Stage planetaryGear Ratio 216 : 1Clutch Sliding ring gearBraking Action: Automatic in the drumFairlead Aluminum hawse fairleadSynthetic Rope 3/8” x 85’ Drum Size 2.5” x 9”Dimensions 22.16” x 6.38” x 7.72”BoltPattern 10”x4.5”N.W. 66LBs

Line Pull:

Line Speed:

Motor Current:

LbsKgs

FPMMPM

Amps

LINE SPEED & MOTOR CURRENT(FIRST LAYER)

0 4000 6000 8000 100000 1814 2722 3629 4309

29.5 15.1 13.1 11.2 9.59 4.6 4 3.4 2.970 210 260 320 380

M

Layer of Cable

Rated Line Pull Per Layer

Cable Capacity Per Layer:

LbsKgsFt

LINE PULL & CABLE CAPACITY1 2 3 4

10000 8070 7250 66004536 3660 3289 299417.7 40.7 67.9 855.4 12.4 20.7 26