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Bushranger COVERT RWC100S Owner's Manual

Vehicle recovery winch
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OWNERS MANUAL

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Summary of Contents for Bushranger COVERT RWC100S

  • Page 1 RWC100S | RWC100W OWNERS MANUAL...
  • Page 2 We reserve the right to make changes without notice because of continued product improvement. Your Bushranger winch has been designed to give safe and dependable service if operated according to the instructions. Please read and understand this manual before installation and operation of the winch.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Warnings & Safety Specifications Installation Operational Checklist (Prior to use) Winch Products/Accessories Winching Principles Winch Operation Maintenance Troubleshooting Winch Assembly & Parts List Warranty...

  • Page 4: Warnings & Safety

    • Do not use the winch as a lifting device or a hoist for vertical lifting and moving people. • Ensure that the winch is connected to the correct voltage (12VDC only). | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 1...
  • Page 5 Always inspect the hook, latch and pin prior to use. Do not use if there are any signs of excess distortion or bending. • Ensure the pin of the hook is secured using a correctly installed split/cotter pin. WRONG FITMENT CORRECT FITMENT Overwound Underwound | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 2...

  • Page 6: Specifications

    Electrophorus Pre Treated Black Satin Powder Coated Finish WATERPROOF RATINGS IP68 Winch Motor and Gearbox WARRANTY Limited Lifetime Warranty (7 Year Warranty on Electrical Components) CERTIFICATIONS 4 HOLES ∅11(0.43") 254.0mm (10") 167.6mm (6.6”) 160.7mm (6.3”) | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 3...
  • Page 7 6460 19.8 254.0mm (10") m (6.6”) 160.7mm (6.3”) 254.0mm (10") 167.6mm (6.6”) 160.7mm (6.3”) 2490 5489 227.0mm (8.9") 171.2mm (6.74") 227.0mm (8.9") 171.2mm (6.74") 208.6mm (8.2") 582.3mm (23") 208.6mm (8.2") 582.3mm (23") | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 4...

  • Page 8: Installation

    Note: Four (4) M10 x 1.50 pitch 10.9 grade high tensile steel bolts (supplied) must be used in order to sustain the loads imposed on the winch mounting. Torque Settings (Maximum) M10 x 1.5 – 10.9 Grade 44 N.m | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 5...
  • Page 9 22.5° increments to allow for the clutch handle to be orientated to best suit the installation requirements. Fitment guides for common vehicles are available via bushranger.com.au. Loosen and partially remove the 4 x bolts (see important note and red arrows below) that secure the two gearbox sections to the winch.
  • Page 10 PLEASE CONSULT KINGSLEY ENTERPRISES Third Angle Projection 01/01/2001 ENGINEERING DEPARTMENT FOR FURTHER Scale: Sheet Size: Approved: Date: Part No: Drawing No: 2000 + mm CLARIFICATION IF REQUIRED All Angles REMOVE ALL BURRS AND SHARP EDGES | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 7...
  • Page 11 The earth wire should be disconnected during installation. Wiring Diagram The Bushranger COVERT winch is supplied with the power cables pre-wired to the winch and with a universal fitment isolation switch. Find a suitable location close to the vehicle’s battery to mount the isolation switch utilising the supplied bracket.

  • Page 12: Operational Checklist (Prior To Use)

    Note: There is a red indicator mark on the rope identifying the maximum available length. • Place the hand controller, 5m lead, red isolation switch key, and these instructions in the glove box (or alternate location in the vehicle cab) together. | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 9...

  • Page 13: Winch Products/Accessories

    Optional Winch Products/Accessories It is recommended to use Bushranger winch and recovery products that have been designed and tested alongside this winch. Tree Trunk Protector Strap RTS11 A tree trunk protector strap is useful for connecting a rope to almost any anchor point but is primarily designed to prevent a tree from ring barking.

  • Page 14: Winching Principles

    Can be used in both Snatch Strap or Winching recoveries. Winching Principles NOTE: Bushranger 4X4 Gear recommend that prior to using this recovery equipment, users should undertake formal training from an accredited industry body in winch use and vehicle recovery.
  • Page 15 = (3,000kg X 0.52) + (3,000kg X 0.71) = 1,560kg + 2,130kg = 3,690kg of effect required to recover the vehicle. Note: A gradient of 10% is a rise of one metre in ten metres (Height/Distance). | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 12...
  • Page 16 A full drum delivers the MED. LOAD maximum speed and the minimum load. For this reason, automotive winches are FIRST LAYER MIN. SPEED rated at their first layer capacities MAX. LOAD | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 13...

  • Page 17: Winch Operation

    Disengaged Powering Out (No Load) The unique Proportional Brake in the Bushranger COVERT winch allows for effortless powering OUT under NO LOAD, with no concern for damage occurring to the brake or motor. In most circumstances powering out the rope may be quicker and easier than free spooling by hand.
  • Page 18 The wireless hand controller can also be used in wired Mode. Connect the winch hand controller cable to the control plug and the hand controller. When the cable is plugged in, the “Wired” light will illuminate RED. | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 15...
  • Page 19 Do not disengage the clutch if powering out in Step 3. Please note: The Bushranger COVERT winch can be powered out under no load, and in most situations it may be faster. Pay careful attention not to allow the rope to become “over wound”...
  • Page 20 9) Use a Recovery Damper Lay a recovery damper or heavy blanket over the rope in the middle third of its length. If a rope failure occurs, the damper can prevent the rope from whipping. | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 17...
  • Page 21 13) Disconnect the Hand Controller Disconnect the wireless mode (See page 15), or unplug the hand controller cable at both ends. Store the hand controller in a safe, dry and easily accessible place. | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 18...
  • Page 22 | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 19...

  • Page 23: Maintenance

    Under normal conditions, factory lubrication will suffice. If re-lubrication of the gear box is necessary after repair or disassembly, use Shell EP2 or equivalent grease. The clutch handle can be lubricated regularly with light oil. | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 20...
  • Page 24 Thread the rope through the hawse fairlead and under the drum, then insert the rope all the way through the hole in the end of the drum with 15-20cm protruding out. | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 21...
  • Page 25 A red painted section of the rope warns the operator that there is 3 meters of rope left on the drum. Do not wind out past this point. TAPE TAPE HERE | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 22...

  • Page 26: Troubleshooting

    Stop the winch operation and Over load operation reduce a load Long period of operation Allow to cool Motor runs Damaged motor Replace or repair motor extremely hot Damaged or inoperative brake Replace or repair brake | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 23...

  • Page 27: Winch Assembly & Parts List

    Winch Assembly - Covert 10 Synthetic | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 24...
  • Page 28 Third Stage Retaining Circlip Nut M12*1.25 Input Shaft Bearing Hand Strap Gearbox Cover Ratchet Bearing Synthetic Rope 3/8”Hook Anti-Wear Washer Remote Control Cable M10 Nyloc Nut Hexagon socket flat head screw M10*50 | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 25...
  • Page 29 Receiver Fourth Stage Planetary Gear Cross recessed pan head tap- Assembly ping screw 3.5*16 Drum Support Gearbox Side Cross recessed pan head tap- ping screw 3.5*12 Spring Washer φ5 Control Box Cover | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 26...
  • Page 30 Winch Assembly - Covert 10 Wire | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 27...
  • Page 31 Receiver Fourth Stage Planetary Gear Cross recessed pan head tap- Assembly ping screw 3.5*16 Drum Support Gearbox Side Cross recessed pan head tap- ping screw 3.5*12 Spring Washer φ5 Control Box Cover | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 28...
  • Page 32 Stop Washer M12 Gearbox Cover Ratchet Bearing Nut M12*1.25 Anti-Wear Washer Hand Strap Synthetic Rope 3/8”Hook Remote Control Cable M10 Nyloc Nut Hexagon socket flat head screw M10*50 Hexagon socket flat head screws M10*40 | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 29...

  • Page 33: Warranty

    Kingsley product. If further information or investigation is required or if the claim does not meet the requirements under our warranty, we’ll let you know. | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 30...
  • Page 34 Kingsley Enterprises Pty Ltd (ABN 23 001 592 749) E: sales@bushranger.com.au We/Us A: 6A Brooks Road, Ingleburn NSW 2565 P: 1800 654 767 W: www.bushranger.com.au The purchaser of the Kingsley product from a Kingsley outlet | BUSHRANGER COVERT VEHICLE RECOVERY WINCH Page 31...
  • Page 36 Kingsley Enterprises PTY. LTD. Free Call | 1800 654 767 (Australia Only) International | +61 2 8700 0400 Email | sales@bushranger.com.au Address | 6A Brooks Road, Ingleburn NSW 2565 0275-22O...

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Covert rwc100w

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