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Summary of Contents for X-POWER XP40
- Page 2 Thank you very much for choosing an X-Power™ product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it.
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Page 3: Table Of Contents
Table of Contents Symbols Index ............................3 Important Safety Information ....................... 4 Specific Operation Warnings ....................... 4 Intended Use ............................6 Winch Overview & Terms ........................6 Installation Instructions ........................6 Before Each Use ..........................13 Operating Instructions ........................13 After Each Use ............................. -
Page 4: Important Safety Information
Important Safety Information ⚠WARNING WORK AREA SAFETY Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit. Cluttered, wet, or dark work areas can result in injury. Using the electric winch in confined work areas may put you dangerously close to other cutting tools and rotating parts. -
Page 5: Specific Operation Warnings
Specific Operation Warnings ⚠WARNING GENERAL SAFETY To prevent injury or property damage, read and understand all instructions before operating winch. Wear ANSI Z87.1 compliant safety goggles and heavy-duty leather work gloves during operation. Do not exceed the rated load capacity. Be aware of dynamic loading! Sudden load movement may briefly create excess load causing product failure. -
Page 6: Intended Use
Disconnect battery cables before working near the rope, drum, fairlead or load to prevent accidental starting. Keep rope straight to avoid kinking the rope. Keep children and bystanders away while operating. Hook onto the object using a pulling point, tow strap, or chain. Do not wrap the rope around the object and hook onto the rope itself. -
Page 7: Winch Overview & Terms
Winch Overview & Terms Become familiar with your winch before you begin installation and operation. See the illustrations below with common winch terms. MOTOR DRUM CLUTCH DIAL CONTACTOR ROPE POWER CABLES CORDED REMOTE Installation Instructions ⚠WARNING Read the entire Important Safety Information section at the beginning of this manual, including all text under subheadings, before setting up or using this electric winch. - Page 8 Before drilling, verify that the installation surface has no hidden components or structural pieces that will be damaged. NOTE: This winch can generate extreme forces. Select a location that can withstand the rated capacity without damage or weakening. Steel reinforcement plates may be needed or a certified welder may need to weld on additional bracing, depending on the mounting location.
- Page 9 Handlebar Switch Installation Handlebar Switch Hardware ITEM DESCRIPTION QTY. MOUNT HANDLEBAR BRACKET SWITCH PWS BRACKET MOUNTING SWITCH HANDLEBAR PWS LINK BRACKET SWITCH HANDLEBAR PWS Screw Machine Button Head Phillips ZN M3x6 Washer Lock Internal-Tooth ZN M3 Capscrew Socket Hex Blk M5x25 Capscrew Socket Hex Blk M5x18 Nut Nylock Hex ZN M5 Washer Lock External-Tooth ZN M5 10 Splice Electrical...
- Page 10 ITEM DESCRIPTION QTY. U-Bolt Blk 38mm ID x 50mm HT x M6 Splice Electrical Washer Flat ZN M6 Cap-screw Socket Hex Blk M6x20 Nut Nylock Hex ZN M6 Corded Remote Socket Installation Remote Socket Hardware ITEM DESCRIPTION QTY. Screw Button Hd M3x18 Washer Flat ZN M3 Nut Nylock Hex ZN M3 Splice Electrical...
- Page 11 Wiring: To prevent serious injury, from explosion, due to sparking at the battery connection, disconnect the Battery Cables before making other wiring connections. To prevent serious injury from leaking battery acid, do not use a dirty, corroded, or leaking battery. Only use a 12V automotive (or equivalent) battery that is in good condition.
- Page 12 Attach the blue and yellow cables to their corresponding terminals on the winch. Apply Di-Electric Grease to protect connections from corrosion. Install the control wiring or switch wiring harnesses. NOTE: Use the images shown above to make all electrical wiring connections for the controls included with your specific winch kit.
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Page 13: Before Each Use
Stop approximately every minute to check rope is winding uniformly on the drum. Make sure vehicle is in park with parking brake applied before exiting vehicle. Do not check, touch, or attempt to reposition rope with load on winch rope. Winch Control Overview：... - Page 14 Read the entire Important Safety Information section at the beginning of this manual, including • all text under subheadings, before setting up or using this electric winch. The instructions that follow are basic guidelines only and cannot cover all situations •...
- Page 15 10. Place a heavy cloth (such as a jacket) or Damper (sold separately) over the rope span to help absorb the force released if the rope breaks. 11. Re-engage the clutch by moving the clutch handle to the engaged position (see image below). ENGAGE ...
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Page 16: After Each Use
16. Do not operate the winch at extreme angles. Do not exceed the angles shown below for a roller fairlead. For a hawse fairlead, the angle should be as close to straight as possible. 17. If the object to be pulled must be pulled at an angle in relation to the winch, use a pulley (sold separately) and an anchor point directly in front of the winch, as shown in... -
Page 17: Maintenance
Maintenance ⚠WARNING To prevent serious injury, disconnect the battery cables before performing any inspection, • maintenance, or cleaning procedures. To prevent serious injury from winch failure, do not use damaged equipment. If an abnormal • noise or vibration occurs, have the problem corrected before further use. When operating a steel cable winch, be sure to check and maintain cable. -
Page 18: Troubleshooting
Troubleshooting ⚠WARNING Follow all safety precautions whenever diagnosing or servicing the tool. • Disconnect power supply before service. • Use the table below to troubleshoot problems before contacting service personnel or your local dealer. If the problem continues after troubleshooting, call your local dealer for assistance. Failure Possible Cause Corrective Action... -
Page 19: Parts Diagram
Parts Diagram Parts List: Rev.081022 Page 19 of 22 FUS-20852000-0031... - Page 20 Normal maintenance is not covered by this warranty and is not required to be performed at a facility or by a person authorized by X-Power. Other exclusions The warranty excludes the following: ...
- Page 21 X-Power reserves the right to change product design without notice. In situations in which X-Power has changed a product design, X-Power shall no obligation to upgrade or otherwise modify previously manufactured products.
- Page 22 Rev.081022 Page 22 of 22 FUS-20852000-0031...
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