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3.3
ElECTRICAl lEAD WIRE ATTAChMENT
3.3.1
Disconnect the battery.
3.3.2
The battery lead wires should be routed to the battery. To protect against abrasion apply several layers of electrical tape where wiring
may come into contact with sharp metal parts of the vehicle.
All connections to motor, solenoids and battery earths require good, clean tight connections. connect the red lead to the positive (+)
terminal and the black lead to the negative (-) terminal of the battery.
3.3.3
The relay may be mounted remotely as space requires. If it is mounted more than 700mm (27') from the winch, use larger diameter wire.
3.3.4
Reconnect the battery, positive terminal first, then the negative. Rotate the clutch lever to the "disengaged position". Pull several metres
of cable off the drum. Return the clutch lever back to the "engaged position". Plug in the remote switch assembly, refer to fig.9. Switch
the hand control to "rope out" position. Pull the trigger momentarily to check cable drum rotation direction. If the drum rotates in the
wrong direction, recheck the wiring.
WARNING! Double check the wiring. Incorrect wiring could result in motor burn out and/or personal injury.
4.
OPERATING INSTRUCTIONS
WARNING! The switch assembly must be kept free of dirt and moisture to ensure safe operation.
4.1
The hand held switch activates power to the winch motor. To connect the remote control remove the waterproof plug cover and insert
the control cable plug and turn the securing ring clockwise to lock see fig.9. The plug on the control cord is keyed and will only fit the
socket one way. The switch trigger returns to the "Off" position when released. To change direction, press the rocker in the other
direction, see fig.8.
Fig.8
4.2
PUllING OUT ThE WIRE ROPE
The wire rope has been installed on the winch under minimal load at the factory. It must be re-spooled onto the drum so the outer
layers will not draw down into the inner layers, causing damage to the rope.
4.2.1
Pull and rotate the clutch lever to the, "disengaged" position as shown in fig.10. If there is a load on the wire rope, the clutch lever
may not turn easily. DO NOT force the clutch lever. Release the tension on the wire rope by paying out some of the wire rope, then try
releasing the clutch.
4.2.2
Pull out the wire rope and secure it to an anchor or a load.
4.2.3
Check that there are at least five turns of wire rope left on the drum.
4.2.4
Re-engage the drum by rotating the clutch lever to the "engaged" position, see fig.10.
WARNING! The lever must be in the engaged position and locked before winching.
4.2.5
Your winch incorporates a proportional friction-type brake. After winching in a load, this mechanism holds the load, up to the rated
capacity of the winch. While powering out the load, the winch controls the rate of speed by applying the brake in proportion to the
amount of load on the wire rope. This results in heavier loads powering-out more slowly than lighter loads. Similar to the friction-type
brakes in your car which can generate heat if used for a long time, the winch brake can generate heat if used to power-out a load
for a long period of time. To ensure optimum winch performance, always limit powering-out a load to one minute and allow the brake
to cool for fifteen minutes before continuing to winch. Under normal use the brake mechanism should not require any adjustment.
Should the brake fail to hold a load or maintain a constant rate of speed during a powering-out operation, the brake pad may be worn
and require replacement.
4.2.6
Keep a tightly wound wire rope drum. Do not allow the windings on the drum to become loosely wound. A loosely wound drum allows
wire rope under load to work its way down into the layers of wire rope on the drum. When this occurs, wire rope may become wedged
within the body of the windings causing damage to the wire rope. To prevent this keep the wire rope tightly and evenly wound on the
drum at all times. Rewind the rope under tension after each use. one method is to attach the hook to a stationary object at the top of a
small hill or incline and winch your vehicle up the incline.
4.2.7
DO NOT allow the motor to overheat. The winch is designed for intermittent use only. During long or heavy pulls the motor will get hot,
with its internal parts hotter than the case. To check motor temperature, stop winching and carefully touch the end of the motor. If
uncomfortably warm, allow the motor to cool before continuing. Keep engine running to recharge battery during this break.
4.2.8
The pull required to start a load moving is often much greater than the pull to keep it moving. Avoid stopping and starting during a pull
except when required by motor temperature.
4.2.9
Prevent kinks in the cable before they occur, by keeping an even tension on the cable when paying in. (Refer to 4.2.6).
4.2.10 equipping the winch with a roller fairlead (supplied) will substantially reduce wear on the wire rope during angle pulls, because rollers
eliminate heavy rubbing and abrasion to the wire rope, see fig.11.
NOTE: Never winch your vehicle in gear or in park, which would damage your vehicle's transmission.
Never wrap the wire rope around an object and hook the cable back onto itself, this can cause damage to the object being pulled and
kink or fray the wire rope.
Keep hands, clothing, hair and jewellery clear of the drum and cable when winching.
Never use the winch if the cable is frayed, kinked or damaged.
Never allow anyone to stand near the cable, or in line with the cable or behind the winch while it is under power. If the cable should slip
or break it can suddenly whip back towards the winch, causing great danger for anyone in the area. Always stand well to the side while
winding and use a wire rope dampener.
DO NOT leave the switch plugged in when the winch is not in use.
ChECK ThE WINCh ThOROUGhlY AND CAREFUllY BEFORE OPERATING!
Fig.9
Fig.10
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