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Bushranger REVO MKII Owner's Manual

Vehicle recovery winch
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Summary of Contents for Bushranger REVO MKII

  • Page 1 RWM100S | RWM100W | RWM120S | RWM120W 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 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 Ensure that the winch is connected to the correct voltage (12VDC only). • Do not exceed the maximum line pull ratings shown in this manual. Shock loads must not exceed these ratings. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 4...
  • Page 5 • Ensure the pin of the hook is secured using a correctly installed split/cotter pin. WRONG FITMENT CORRECT FITMENT ISOMETRIC VIEW N.T.S. ISOMETRIC VIEW N.T.S. Overwound Underwound Underwound Overwound | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 5...

  • Page 6: Specifications

    153mm (4.5") (6.02") Wired R 167mm (6.57") 254mm (10.0") 161mm (6.34") | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 6 Mass (g): Finish: COPYRIGHT UNLESS OTHERWISE INDICATED ALL FILLET WELDS ARE 5MM IN SIZE ALL RIGHTS RESERVED. THIS DRAWING MUST NOT BE...
  • Page 7 Performance - 1st layer of drum (10,000lb REVO MKII) LINE PULL REVO MKII LINE SPEED MOTOR CURRENT ft/min m/min Amps 49.2 15.0 4000 1814 6000 2722 8000 3629 10,000 4536 Performance - Pull by layer SYNTHETIC Layer Total rope on drum...
  • Page 8 600mm (23.62") 194mm CERTIFICATIONS 112mm (4.41") 4 Holes 11mm (0.43") 65mm (2.56" 114.3mm 153mm (4.5") (6.02") Wired Re 254mm (10.0") 161mm (6.34") 184mm (6.57") | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 8 Mass (g): Finish: UNLESS OTHERWISE INDICATED ALL...
  • Page 9 Performance - 1st layer of drum (12,000lb REVO MKII) LINE PULL REVO MKII LINE SPEED MOTOR CURRENT ft/min m/min Amps 65.6 20.0 4000 1816 10.5 6000 2722 8000 3629 10,000 4536 12,000 5443 Performance - Pull by layer SYNTHETIC Layer...

  • Page 10: Installation

    4 x M10x35mm Hex Head bolts (for foot down installation) • 2 x M10x50mm Button Head Bolts (for mounting Hawse Fairlead in foot forward mounting – REVO MKII 10S & 12S only) • 2 x M10x45mm Button Head Bolts (for mounting Roller Fairlead in foot forward mounting –...

  • Page 11: Control Box Mounting

    Control Box mounting The REVO MKII Control Box is designed with multiple mounting options to suit a wide variety of vehicles and bullbars. Provided with a range of fasteners to suit different mounting options including: Tie bar mounting (shown in green), directly to the winch;...
  • Page 12 A minimum of 2x fasteners should be used, but it is recommended to use 3 or 4 to ensure a solid, robust mounting outcome is achieved. ISOMETRIC VIEW N.T.S. Control Box - Bullbar Mounting | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 12...

  • Page 13: Important Note

    Reinstall and tighten all bolts to Max 19Nm with torque wrench. STEP 1 STEP 2 Important note: DO NOT USE a Power Tool such as an impact driver. This may lead to the stripping of bolt threads or heads of bolts. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 13...

  • Page 14: Motor Rotation

    The minimum requirement for a 12 Volt DC battery is 650 cold cranking amps. • Do not lean over batteries while making connections. • The earth wire should be disconnected during installation. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 14...

  • Page 15: Wiring Installation

    5A Fuse 4 Pin Connector Pink Control Box Antenna Plug (WINCH IN) (WINCH OUT) Isolation Contactor Switch Wireless (Blue) (Yellow) (Red) Receiver Winch Motor Vehicle Battery Motor Ground Terminal Black 2AWG | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 15...

  • Page 16: Installation Checklist

    Note: There is a red indicator mark on the rope identifying the maximum available length. • Place the hand controller, 5m lead and these instructions in the glove box (or alternate location in the vehicle cab) together. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 16...
  • Page 17 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 18 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 19 = (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 REVO MKII VEHICLE RECOVERY WINCH Page 19...

  • Page 20: Load Rating

    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 REVO MKII VEHICLE RECOVERY WINCH Page 20...

  • Page 21: Winch Operation

    Underwound Powering Out (No Load) The unique Proportional Brake in the Bushranger REVO MKII 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 22 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. Hand Controller - Battery Change | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 22...
  • Page 23 Do not disengage Disengaged Clutch the clutch if powering out in Step 3. Please note: The Bushranger REVO MKII 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 24 Use a shackle to lock both ends of the tree trunk protector and then attach to the hook. Please note: The winch line is now live. Do not step over or cross the rope. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 24...
  • Page 25 12) After Winching Once the vehicle is recovered and safely secured, wind the remaining rope back onto the drum tightly and evenly and secure the hook firmly. Check rope/parts for wear or damage. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 25...
  • Page 26 • Always keep clear of the winch, rope, hook and fairlead while winching. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 26...
  • Page 27 • A winching operation requires extra consumption of battery power, so always maintain your battery and ensure it is in good condition. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 27...

  • Page 28: 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 REVO MKII VEHICLE RECOVERY WINCH Page 28...

  • Page 29: Maintenance Schedule

    Brake Ability to hold loads Visual Reasonable actuation Gears Smooth operation Visual, auditory Reasonable actuation Damaged or Visual evidence Seals Free of wear or damage worn seals of wear | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 29...
  • Page 30 Wind the red section of rope onto the drum tightly and evenly (under hand tension) to have a minimum of five (5) wraps of wire rope on the drum. | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 30...
  • Page 31 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 (Black). View from rear of winch. Rope through drum Rope Winding | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 31...

  • Page 32: Troubleshooting

    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 REVO MKII VEHICLE RECOVERY WINCH Page 32...
  • Page 33 Winch Assembly - REVO MKII 10,000LB Synthetic | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 33...
  • Page 34 REVO MKII 10,000LB Synthetic Model Parts List Description Item No: Description Gearbox End Socket Head Third Stage Rotating Ring Cap Screw M5x80mm Gear Spring Washer M5 Clutch Pin Gearbox End Cover Clutch Pin O Ring Small O Ring Seal Clutch Pin O Ring Large...
  • Page 35 Flat Washer M5 Motor Cover Socket Head Spring Washer M5 Cap Screw M5x50mm 10K Motor Assembly Nyloc Nut M5 Motor End Cover Contactor Earth Wire Wireless Receiver Red 2AWG Power Cable 500mm | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 35...
  • Page 36 Winch Assembly - REVO MKII 10,000LB Wire | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 36...
  • Page 37 REVO MKII 10,000LB Wire Model Parts List Item No: Description Item No: Description Gearbox End Socket Head Third Stage Rotating Ring Cap Screw M5x80mm Gear Spring Washer M5 Clutch Pin Gearbox End Cover Clutch Pin O Ring Small O Ring Seal...
  • Page 38 Flat Washer M5 10K Motor Cover Spring Washer M5 Motor Cover Socket Head Cap Screw M5x50mm Nyloc Nut M5 10K Motor Assembly Contactor Earth Wire Motor End Cover Red 2AWG Cable 500mm | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 38...
  • Page 39 Winch Assembly - REVO MKII 12,000LB Synthetic | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 39...
  • Page 40 REVO MKII 12,000LB Synthetic Model Parts List Description Item No: Description Gearbox End Socket Head Third Stage Rotating Ring Cap Screw M5x80mm Gear Spring Washer M5 Clutch Pin Gearbox End Cover Clutch Pin O Ring Small O Ring Seal Clutch Pin O Ring Large...
  • Page 41 Flat Washer M5 Motor Cover Socket Head Spring Washer M5 Cap Screw M5x50mm Nyloc Nut M5 12K Motor Assembly Contactor Earth Wire Motor End Cover Wireless Receiver Red 2AWG Cable 500mm | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 41...
  • Page 42 Winch Assembly - REVO MKII 12,000LB Wire | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 42...
  • Page 43 REVO MKII 12,000LB Wire Model Parts List Item No: Description Item No: Description Gearbox End Socket Head Third Stage Rotating Ring Cap Screw M5x80mm Gear Spring Washer M5 Clutch Pin Gearbox End Cover Clutch Pin O Ring Small O Ring Seal...
  • Page 44 Socket Head Cap Screw 12K Motor Cover M5x20mm Flat Washer M5 Motor Cover Socket Head Cap Screw M5x50mm Spring Washer M5 12K Motor Assembly Nyloc Nut M5 Motor End Cover Contactor Earth Wire | BUSHRANGER REVO MKII VEHICLE RECOVERY WINCH Page 44...
  • Page 45 BUSHRANGER PRODUCTS - WARRANTY POLICY Our Warranty We warrant to you that the Bushranger product is free from defects in workmanship and materials for the warranty period. Fitting and use Please ensure you: a. Fit the Bushranger product in accordance with the product information and all relevant vehicle safety and compliance laws b.
  • Page 46 The benefits to you under our warranty are in addition to any other rights and remedies you are entitled to under relevant consumer laws. Our warranty replaces any other warranty given by Bushranger or it’s supplier in respect of the Bushranger product.
  • Page 48 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 0284-23O...

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