Product Manual
Table Of Contents
- GETTING TO KNOW YOUR WINCH
- The winch and its all-derivative types are rated at rated capacity when spooling the first rope layer on the drum. Overloading can damage the winch/motor/ or wire rope. For loads over 70% of rated line pull, we recommend the use of the pulley bloc...
- The vehicle engine should be kept running during operation of the winch to minimize battery drain and maximize power and speed of the winch. If the winch is used for a considerable amount of time with the engine off, the battery may be drained and ...
- Get to know your winch before you actually need to use it. We recommend that you set up a few test runs to familiarize yourself with rigging techniques, the sounds your winch makes under various loads, the way the cable spools on the drum, etc.
- Inspect the wire rope and equipment before each use. A frayed or damaged rope must be replaced immediately. Use only the manufacturer’s replacement rope with the exact specifications.
- Inspect the winch installation and bolts to ensure that all bolts are tight before each operation.
- Never connect the cable back to itself. This will cause cable damage. Always use a snatch block, sling or chain of suitable strength as shown in the illustrations.
- Store the remote control inside your vehicle in a place that it will not be damaged.
- Any winch that appears to be damaged in any way, is found to be worn, or operates abnormally shall be removed from service.
- Pull only on parts of the vehicle as specified by the vehicle manufacturer.
- Only attachments and/or adapters supplied by the manufacturer shall be used.
- Whenever before your winch start to working, please slightly test-run your winch in two direction, even if the winch drum only round a few degree of angle, ensure the winch is well-balanced, especially after you operated the clutch, test-running win...
- WINCHING TECHNIQUES A-Z
- a. Take time to asses your situation and plan your pull.
- b. Put on gloves to protect your hands.
- c. Disengage the clutch to allow free-spooling and to save energy.
- d. Attach the hand saver hook to the clevis hook.
- e. Pull out the wire rope to your desired anchor point using the hand saver hook.
- f. Secure the clevis hook to the anchor point: Sling, chain or snatch block. Do not attach the hook back onto the wire rope.
- g. Engage the clutch.
- h. Connect the remote control to the winch.
- i. Start your engine to ensure power is being replenished to the battery.
- j. Power in the wire rope guiding the wire under tension to draw up the slack in the wire. Once the wire is under tension stand well clear. Never step over the wire rope.
- k. Disengage the clutch to allow free-spooling and to save energy.
- l. Inspect the wire rope. Make sure there are at least 5 wraps of wire rope around the winch drum.
- m. Drape a blanket or jacket over the wire rope approximately 5 to 6 feet from the hook. Open the hood for added protection.
- n. Clear the area. Make sure all spectators are back and that no one is directly in front or behind the vehicle or anchor point.
- o. Begin winching. Be sure that the wire rope is winding evenly and tightly around the drum. The vehicle that is being winched can be slowly driven to add assistance to the winching process. Avoid shock loads; keep the wire rope under tension.
- p. The vehicle to be winched should be placed in neutral and the emergency brake released. Only release the brake pedal when under full tension. Avoid shock loads to the winch. This can damage the winch, rope and vehicle.
- q. The winch is meant for intermittent use. Under full load with a single line rig do not power in for more than a minute without letting the motor cool down for a few minutes and then resume the winching operation.
- r. The winching operation is complete once the vehicle is on stable ground and is able to drive under its own power.
- s. Secure the vehicle. Be sure to set the brakes and place the vehicle in park.
- t. Release the tension on the wire rope. The winch is not meant to hold the vehicle for long periods of time.
- u. Disconnect the wire rope from the anchor.
- v. Rewind the wire rope. Make sure that any wire already on the drum has spooled tightly and neatly. If not, draw out the wire and re-spool from the point where the rope is tight.
- w. Keep your hands clear of the winch drum and fairlead as the wire rope is being drawn in.
- x. Secure the hook and hook strap.
- y. Disconnect the remote control and store in a clean, dry place.
- z. Clean and inspect connections and mounting hardware for next winching operation.
- WINCH ASSEMBLY AND MOUNTING
- WINCH ACCESSORIES YOU WILL NEED
- RIGGING TECHNIQUES
- Self-Recovery
- 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 Fig 3.1
- CAUTION Do not winch from an acute angle as the wire rope will pile up on one side of the drum causing damage to wire rope and the winch. Fig 3.2
- 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.
- 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 Fig 3.3
- For pulls over 70% rated line pull, we recommend the use of the snatch block/pulley block to double line the wire rope. Fig 3.4
- This reduces the load on the winch and the strain on the rope by up to 50% depending on the included angle.
- WARNING - Never use your winch for overhead hoisting or for lifting people or moving people.
- WINCH WORKING DEMONSTRATION
- REPLACING THE WIRE ROPE
- 1. MAINTENANCE
- SUGGESTED ACTION
- XT2500
- WINCH PARTS LIST
- XT2500
- 2
- 2
- WINCH PARTS LIST
- XT3500
- 2
- 2
- WINCH PARTS LIST
- XT4500
- 2
- 2
- 50
- 140
- 150
- 34.0(10.4)
- 150
- 170
- 29.8(9.1)
- 170
- 220
- 44.6(13.6)
13
WINCH ASSEMBLY DRAWING
SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION
Motor does not
turn on
-Switch Assembly not
connected properly
-Loose battery cable
connections
-Defective Switch
Assembly
-Defective motor
-Water has entered motor
-Insert Switch Assembly all the way into
the connector.
-Tighten nuts on all cable connections.
-Replace Switch Assembly.
-Check for voltage at armature port with
Switch pressed. If voltage is present,
replace motor.
-Allow to drain and dry. Run in short
bursts without load until completely dry.
Motor runs but
cable drum does
not turn
-Clutch not engaged
-Turn clutch to the “In” position. If problem
persists, a qualified technician needs to
check and repair.
Motor runs slowly
or without normal
power
-Insufficient current or
voltage
-Battery weak recharge. Run winch with
vehicle motor running.
-Loose or corroded battery cable
connections. Clean, tighten, or replace.
Motor overheating
-Winch running time too
long
-Allow winch to cool down periodically.
Motor runs in one
direction only
-Defective Switch
Assembly
-Loose or corroded battery cable or motor
cable connections. Clean and tighten.
-Repair or replace switch assembly.