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)
15
1
T0350001
2
Terminal Protector
2
T0350100-D
1 Motor Assembly
Used in D and A type winch
T0350100-U
Used in U type winch
3
T0350002
2
Bushing-Drum
4 T0350003 1
CouplingⅠ
5
T0350004
1
Spring
6
T0350005
1
CouplingⅡ
7
T0350006
1
Spring
8
T0350200
1
Drum Assembly
9
T0350007
1
Screw M6 x 8
10
T0350008
2
Screw M6 x25
11
T0350009
4
Locking Washer Φ6
12
T0350010
2
Tie Bar
13
T0350011
1
Screw M4 x15
14
T0350012
2
Locking Washer Φ4
15
T0350013
1
Stand Bar
16
T0350014
2
Screw M6 x30
17
T0350015
1
Screw M4 x30
18
T0350016
1
End Bearing
19
T0350017
1
Gasket
20
T0350018
1
Hexagonal Shaft
21
T0350019
1
Gear-Ring
22
T0350300
1
Gear Carrier Assembly(Output)
23
T0350400
1
Gear Carrier Assembly(Intermediate)
24
T0350500
1
Gear Carrier Assembly(Input)
25 T0350020 1
Gear—Input Sun
26 T0350600 1 Gear—Housing And Clutch Handle Assembly
27 T0350021 4
Lock Washer Φ8
28 T0350022 4 Thick Flat Washer Φ8
29
T0350023
4
Screw M8 x 25
30
T0350024
2
Hex Flange Nut M8
31
T0350021
2
Locking Washer Φ8
32
T0350022
2
Thick Flat Washer Φ8
33
T0350700
1
Roller Fairlead
34
T0350025
1
Mounting Channel
35
T0350026
2
Screw M8 x 20
36
T0350027
2
Screw M8 x35
37
T0350022
2
Thick Flat Washer Φ8
38
T0350021
2
Locking Washer Φ8
39
T0350028
2
Hex Flange Nut M8
40
T0250800
1
Cable Assembly
41
T0350029
1
Strap
42
T0350900
1
Control Section Of D Type Winch
By choice
43
T0351000
1
Control Section Of A Type Winch
By choice
44
T0351100
1
Control Section Of U Type Winch
By choice
WINCH ASSEMBLY DRAWING
XT3500