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Table of Contents
Contents
Traveller 2500 - 2500lb Winch Manual
Performance Specifications
Max Line Pull
2500lbs.(1134kgs)
Gear reduction ratio
170:1
Motor
Permanent magnet DC12V motor with 1.1hp output
Overall Dimensions
12.7in.( 323mm) L × 4.45in.( 113mm) W × 4.4in.( 112 mm) H
Drum size
1.46in.( 37mm) D × 3.15in.( 80 mm) L
Cable
45.9ft.(14.0m) L of 3/16in.(4.8mm) D
Net weight
21.7lbs.(9.86kgs)
Product Overview
This winch is equipped with a permanent magnet motor and is designed for intermittent duty general use. This winch is not to be used for industrial lifting or moving people. Improper operation could damage the winch and void the warranty. Free spool clutch is operated by a pull and turn knob, which disengages the gearbox, allowing the cable to be released.
INSTALLATION
Correct installation of the winch is required for proper operation.
- Mount the winch on the mounting channel by using a screw(M8×16mm)(four sets).
- Mount the winch with the mounting channel on the vehicle or other fixed installation by using a screw(M8×1.25×35mm), M8 nut, Φ8 flat washer and Φ8 spring washer(two sets).
This winch must be mounted with the cable in an under wound direction.
Improper mounting could damage the winch and void the warranty.
Connect the red wire to the positive terminal and the black wire to the negative terminal of the battery.
- Check the rotation direction of the drum. Pull and turn the clutch knob to the "FREE SPOOL" position (drum should turn freely by hand). Pull out some cable from the drum, and then turn the clutch knob to the "ENGAGE" position. Press the "OUT" button on the ATV/UTV switch; if the cable is releasing then it is properly connected. Otherwise reverse the wire connections to the motor, and repeat the above-mentioned operation.
The ATV mounting
The UTV mounting
OPERATION
- Pull and turn the clutch knob, so the drum can turn freely by hand.
- Use hand saver bar to hitch the hook of the cable assembly and pull cable to the load. Attach the cable hook to the load.
Check that there are at least five turns of cable remaining on the drum before operation. Ensure the clutch knob is in the engaged position.
Clutch must be fully engaged before winching.
Never operate the clutch while drum is turning. Do not readjust clutch knob as it has been adjusted and permanently locked in place with a thread-locking compound in the factory.
- Press the "IN" button on the ATV/UTV switch to re-spool the cable. Press the "OUT" button to reverse directions. Wait until the motor stops before reversing directions.
- Re-spool the cable after completing the operation.
REPLACING THE CABLE
- Engage the clutch by turning the clutch knob to the "ENGAGE" position.
- When inserting the cable into the drum, insert it into the correct end of the hole provided. Tighten the screws.
- Operate the winch an re-spool the cable around the drum tightly.
To keep the stated tension, be sure the cable is wrapped on the drum tightly.
Always replace damaged cable with manufacturer's identical replacement part.
MAINTENANCE
- Periodically check tightness of mounting bolts and electrical connections. Remove all the dirt or corrosion and always keep clean.
- Do not attempt to disassemble the gearbox. Repairs should be done by the manufacturer or authorized repair center.
- The gearbox has been lubricated using high temperature lithium grease in the factory. No internal lubrication is required except when being repaired.
TROUBLE SHOOTING
| SYMPTOM | POSSIBLE CAUSE | SUGGESTED ACTION |
Motor does not turn on |
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Motor runs but cable drum does not turn |
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Motor runs slowly or without normal power |
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Motor overheating |
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Motor runs in one direction only |
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WINCH ASSEMBLY
WINCH PART LIST
(2500LBS)
| No. | Part # | Qty | Description |
| 1 | P0250100 | 1 | Motor Assembly |
| 2 | P0250001 | 4 | Locking Washer Φ8 |
| 3 | P0250002 | 4 | Cap Screw M8 x 16 |
| 4 | P0250003 | 1 | Transition Shaft |
| 5 | P0250004 | 2 | Tie Bar |
| 6 | P0250005 | 1 | Hexagonal Shaft |
| 7 | P0250006 | 1 | Front Bush Drum |
| 8 | P0250007 | 6 | Spring Washer Φ6 |
| 9 | P0250008 | 1 | Screw M6 x 8 |
| 10 | P0250009 | 2 | Cap Screw M6 x 70 |
| 11 | P0250010 | 1 | Drum |
| 12 | P0250011 | 1 | Rear Bush Drum |
| 13 | P0250012 | 1 | Front Thrust Washer |
| 14 | P0250013 | 1 | Gear Ring Output |
| 15 | P0250200 | 1 | Gear Carrier Assembly |
| 16 | P0250014 | 1 | Gear Ring |
| 17 | P0250015 | 1 | Thrust Washer |
| 18 | P0250016 | 1 | Gear Housing / End Bearing |
| 19 | P0250017 | 1 | Bearing Holder |
| 20 | P0250018 | 1 | Roller Bearing |
| 21 | P0250019 | 1 | Clutch axes |
| 22 | P0250020 | 1 | Cam Clutch Gear |
| 23 | P0250021 | 1 | Spring |
| 24 | P0250022 | 1 | Cover Clutch Housing |
| 25 | P0250023 | 1 | Roller Bearing |
| 26 | P0250024 | 1 | Elastic Collar |
| 27 | P0250025 | 1 | Clutch Handle |
| 28 | P0250026 | 1 | Locking Washer Φ5 |
| 29 | P0250027 | 1 | Cap Screw M5 x 12 |
| 30 | P0250028 | 4 | Cap Screw M6 x 25 |
| 31 | P0250029 | 4 | Hex Flange Nut M8 |
| 32 | P0250030 | 4 | Locking Washer Φ8 |
| 33 | P0250031 | 4 | Thick Flat Washer Φ8 |
| 34 | P0250300 | 1 | Roller Fairlead |
| 35 | P0250032 | 1 | Mounting Channel |
| 36 | P0250033 | 2 | Cap Screw M8 x 20 |
| 37 | P0250034 | 2 | Cap Screw M8 x35 |
| 38 | P0250035 | 1 | Strap |
| 39 | P0250400 | 1 | Cable Assembly |
| 40 | P0250036 | 2 | Terminal Protector |
| 41 | P0250500 | 1 | Control Assembly |
SAFETY PRECAUTIONS
- Never lift people or hoist loads over people. Do not lift items vertically, this winch is designed for horizontal use only.
- Never overload. Be sure all equipment used meets the winch's maximum line pull rating. When double-lining, pulley blocks should be rated for a minimum of two times the winch's line pull rating.
- Do not attempt prolonged pulls with heavy loads. The electric winch is designed for intermittent use only, and should not be used in a constant duty application. Never pull for more than one minute or exceed the rated load. If the winch motor becomes hot to the touch, stop the winch and allow it to cool down for several minutes.
- Never operate winch with less than 5 turns of cable around the winch drum since the cable end may not withstand full load.
- Avoid continuous pulls from extreme angles because this will cause the cable to gather on one end of the drum and damage the cable. Be aware that the winch's line pull capacity is the max line pull of the first layer. Never operate winch pulling a load that exceeds the rated capacity.
- Never hook the cable back to itself because it could damage the cable.
- Be sure the winch is mounted securely on the vehicle or bracket before operation.
- Before moving a load, inspect the cable. Prevent kinks and uneven cable layer before they occur. Apply proper tension to loads under 100lbs.
- Do not move your vehicle to assist the winch in pulling the load. It will be easy to overload, and cause cable damage. Be aware of the danger zone. Keep away from the danger zone during the operation. The danger zone is the area of the winch drum, the fairlead (if fitted), the cable, the pulley block (if used), the hook, and the motor.
- Never approach or span the cable when the winch is under load.
- When using the winch to move a load, place the vehicle transmission in neutral, set vehicle brake, and chock all wheels. The vehicle engine should be running during winch operation so that battery has fully electricity. Never use the winch when there is a lack of voltage.
- Never disconnect free spool cultch when there is a load on the winch.
- Always stand clear of the cable, hook and winch. You should disconnect the clutch first, then use the hand saver bar to hitch the hook to pull the cable.
- Inspect winch, cable, hooks and other accessories frequently. A frayed cable with broken strands should be replaced immediately. Use heavy leather gloves when handling the cable. Do not let the cable slide through your hands. Inspect the cable before use. Mashed, pinched, frayed or kinked areas severely reduce the load-carrying capability. Replacement cables must be re-spooled under 100lbs.
- To keep stated tensile, re-spool the cable around the drum tightly after operation.
- Do not operate winch when under the influence of drugs, alcohol or medication. Always stay alert during operation.
- Wear eye protection and personal protective equipment while operating winch.
- For loads over 50% of rated line pull, the use of the pulley block/snatch block to double the cable is recommended.
![burn hazard]()
Do not operate around potentially flammable liquids, gases, or debris. Sparks may occur, resulting in the ignition of fire.
Do not operate around potentially flammable liquids, gases, or debris. Sparks may occur, resulting in the ignition of fire.Line speed and Motor current
(First layer)
| Line Pull | Line Speed ft./min (m/min) | Motor Current Amps |
| Ibs.(kgs) | 12V DC | 12V DC |
| 0 | 14.1(4.3) | 20 |
| 500(227) | 9.8(3.0) | 55 |
| 1500(680) | 7.5(2.3) | 95 |
| 2500(1134) | 4.3(1.3) | 160 |
Line Pull And Cable Capacity
| Layer | Rated line pull lbs (kgs) | Total rope on the drum ft (m) |
| 1 | 2500(1134) | 6.9(2.1) |
| 2 | 2033(922) | 15.1(4.6) |
| 3 | 1713(777) | 24.3(7.4) |
| 4 | 1480(671) | 34.1(10.4) |
| 5 | 1303(591) | 45.9(14.0) |
Distributed By:
TRACTOR SUPPLY COMPANY
5401 VIRGINIA WAY,
BRENTWOOD, TN37027
For customer support, call: 1-888-376-9601
www.TractorSupply.com
VideosTraveller 2500lb Winch Install Video
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