Winch Manual - Warrior Winches
Contents
1. WINCHES ELECTRICAL WINCH 520000 Assembly amp Operating Instructions CONTENTS INTRODUCTION rer 1 GETTING TO KNOW YOUR WINCH eene 2 3 GENERAL TIPS FOR SAFE 5 WINCHING TECHNIQUES A Z eee 6 WINCH ASSEMBLY AND MOUNTING 0 7 MOUNTING DRAWING CD 9 WINCH ACCESSORIES YOU WILL 9 RIGGING TECHNIQUES 9 WINCH WORKING 1 10 REPLACING THE WIRE nnns 11 MAINTENANCE zer 11 TROUBLE SHOOTING rank hh moras rir oonn nana nrc ia a 12 WINCH ASSEMBLY DRAWING S20000 13 WINCH PARTS LIST 520000 14 SPECIFICATION indu ena iia necne 15 INTRODUCTION Congratulations on your purchase of a high quality winch We design and build winches to strict specifications and with proper use and maintenance will bring you years of satisfying2. Whenever before your winch start to working please slightly test run your winch in two direction even if the winch drum only round a few degree of angle ensure the winch is well balanced especially after you operated the clutch test running winch can make winch in gear WINCHING TECHNIQUES A Z a Take time to asses your situation and plan your pull b Put on gloves to protect your hands c Disengage the clutch to allow free spooling and to save energy d Attach the hand saver hook to the clevis hook e Pull out the wire rope to your desired anchor point using the hand saver hook f Secure the clevis hook to the anchor point Sling chain or snatch block Do not attach the hook back onto the wire rope g Engage the clutch h Connect the remote control switch to the winch i Start your engine to ensure power is being replenished to the battery Power in the wire rope guiding the wire under tension to draw up the slack in the wire Once the wire is under tension stand well clear Never step over the wire rope k Double check your anchors and make sure all connections are secure Inspect the wire rope Make sure there are at least 5 wraps of wire rope around the winch drum m Drape a blanket or jacket over the wire rope approximately 5 to 6 feet from the hook Open the hood of the vehicle for added protection 6 n Clear the area Make sure all spectators are back and that no one is directly in front or b
3. Do not use as a hoist Do not use for overhead lifting WARNING Failure to heed these warnings may result in personal injury and or property damage AAWARNING Use gloves to protect hands when handling the cable Never let the cable slide through your hands A WARNING Never connect the cable back to itself Apply blocks to the wheels of the vehicle when on an incline Duration of winching pulls should be kept as short as possible If the motor becomes uncomfortably hot to the touch stop winching immediately and let it cool down for a few minutes Do not pull for more than one minute at or near the rated load AAXCAUTION If the motor stalls not maintain power to the winch Electric winches are designed and made for intermittent use and should not be used in constant duty applications CAUTION Never disengage the clutch when there is a load on the winch AXCAUTION Use the hand saver hook when handling the hook for spooling or un spooling the wire rope GENERAL TIPS FOR SAFE OPERATION The 2000008 and its all derivative types are rated at 20000lbs capacity when spooling the first rope layer on the drum Overloading can damage the winch motor or wire rope For loads over 7096 of rated line pull we recommend the use of the pulley block snatch block to double the wire rope line This will aid in two ways a reduce the number or rope layers on the drum as well as b reduce the load on the wire rope by as muc
4. load place a blanket or jacket over the wire rope five or six feet from the hook In the event of a broken cable it will dampen the snap back For additional protection open the hood of the vehicle as shown in Fig 3 3 For pulls over 7096 rated line pull we recommend the use of the snatch block pulley block to double line the wire rope Fig 3 4 This reduces the load on the winch and the strain on the rope by up to 5096 depending on the included angle WARNING Never use your winch for overhead hoisting or for lifting people or moving people WINCH WORKING DEMONSTRATION 1 Disengage the clutch by turning the clutch to the CLUTCH OUT position 2 Grab the cable assembly Part 52001000 and pull the cable to the desired length then attach to item being pulled A Caution Always leave at least five turns of cable on the drum Review winch safety warnings and precautions on page 2 3 before continuing 3 Reengage the clutch by turn the clutch assembly Part 52000700 to the CLUTCH IN position if the clutch is not engaged the winch drum must be turned by hand until the clutch is totally engaged 4 Insert the switch assembly Part S2000900 connector onto the control box 5 Test run winch in two directions each direction for one or two seconds 10 6 While standing aside of the tow path hold and operate the switch assembly supplied by your choice To reverse directions wait until the motor sto
5. service WARNING Read study and follow all instructions before operating this winch Failure to heed these instructions may result in personal injury and or property damage Your winch can develop tremendous pulling forces and if used unsafely or improperly could result in property damage serious injury or death Throughout this manual you will find the following symbols for caution warning and danger Pay particular attention to the notes preceded by these symbols as they are written for your safety Ultimately safe operation of this device rests with you the operator A CAUTION This indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This notation is also used to alert you against unsafe practices This indicates a potentially hazardous situation which if not avoided could result in death or serious injury GETTING TO KNOW YOUR WINCH Your winch is a powerful piece of machinery It is important that you understand the basics of its operation and specifications so that when you need to use it you can use it with confidence and safety Below is a list of the components of your winch and their use You should practice using your winch before you are in a situation where you need to use it 1 This winch is engineered for maximum line pull with only one layer of cable spooled onto the winch drum the first layer Motor Your 7 1hp 7 9hp motor is powered by
6. LUTCH OUT position Pull out some cable from the drum and then turn the clutch knob to the CLUTCH IN position to engage the gears Press the cable out button on the power switch If the drum is turning and releasing more cable then your connections are accurate If the drum is turning and collecting more cable then reverse the leads on the motor Repeat and check rotation MOUNTING DRAWING 520000 Red Battery LN Switch fex SEC EP 54 Black Battery i amp EN 01 INCH ACCESSORIES YOU WILL NEED NOT INCLUDED WITH YOUR WINCH Gloves For handling the wire rope and hook strap Anchor Strap Chain Tree saver anchor straps are made of high quality nylon with high tensile strengths up to 15000105 Heavy Blanket place on the cable to absorb energy should the wire rope break RIGGING TECHNIQUES Self Recovery Locate a suitable anchor such as a strong tree trunk or boulder Always use a sling as an anchor point AACAUTION Do not attach the clevis hook back onto the cable as this could cause damage to the cable As shown in Fig 3 1 CAUTION Do not winch from an acute angle as wire rope will pile up on one side of the drum causing damage to wire rope and the winch Fig 3 2 Short pulls from an angle can be used to straighten the vehicle Long pulls should be done with the wire rope at a 90 angle to the winch vehicle When pulling a heavy
7. NG Keep yourself and others a safe distance to the side of the cable when it is under tension The wire rope may break before the motor stalls For heavy loads at or near rated capacity use a pulley block snatch block to reduce the load on the wire rope Never step over a cable or go near a cable under load in tension Don t move the vehicle to pull a load towing on the winch cable This could result in cable breakage Z SWARNING Disconnect the remote control and battery leads when not in use Avoid shock loads by using the control switch intermittently to take up the slack in the wire rope Shock loads can far exceed the rate capacity for the wire rope and drum Z NWARNING When re spooling the cable ensure that the cable spools in the under wind position with the cable entering the drum from the bottom not the top To spool correctly you should keep a slight load on the cable while pushing the remote button to draw in the cable Walk toward the winch not allowing the cable to slide through your hands Do not let your hands get within 12 of the winch while re spooling Turn off the winch and repeat the procedure until a few feet of cable is left Disconnect the remote control and finish spooling by hand by rotating the drum by hand with the clutch disengaged Keep hands clear of the fairlead and drum while the winch is under power WARNING
8. Y DC 12V DC 24 DC 0 19 7 6 0 13 8 4 4 100 40 6000 2722 7 2 2 2 6 9 2 1 220 100 10000 4536 5 6 1 7 5 9 1 8 320 140 12500 5670 4 9 1 5 5 2 1 6 350 180 14000 6350 4 6 1 4 4 6 1 4 380 200 17500 7938 3 0 0 9 3 9 1 2 450 250 20000 9072 3 6 0 9 3 3 1 0 480 265 Line pull and rope capacity in layer Layer Rated line pull lbs kgs Total rope on the drum ft m 1 20000 9072 18 0 6 0 2 16160 7330 40 7 13 0 3 13557 6149 65 9 21 0 4 11677 5297 86 9 26 5 WARRANTY Your winch has been manufactured and tested to the highest standards Please ensure you read and understand the assembly and operating instructions before use Failure to comply with these instructions or any improper use of the equipment will terminate the warranty Please ensure you record the information below Distributor Date of Purchase Invoice No Serial No In the unlikely event you experience problems contact the distributor with this information
9. a 12 24 volt battery and provides power to the gear mechanism which turns the drum and winds the wire rope Winch Drum The winch drum is the cylinder on which the wire rope is stored It can feed or wind the rope depending on the remote winch switch Wire Rope cable Your winch has a 15 32 X87 galvanized aircraft cable designed specifically for load capacity of 20000105 The wire rope feeds onto the drum in the under wind position through the roller fairlead and is looped at the end to accept the clevis hook pin Roller Fairlead When using the winch at an angle the roller fairlead acts to guide the wire rope onto the drum and minimizes damage to the wire rope from abrasion on the winch mount or bumper Mechanic Gear System The reduction gears convert the winch motor power into extreme pulling forces Braking System Braking action is automatically applied to the winch drum when the winch motor is stopped and there is a load on the wire rope A separate mechanical brake applies the braking action Free Spooling Clutch The clutch allows the operator to manually disengage CLUTCH OUT the spooling drum from the gear train free spool Engaging the clutch CLUTCH IN locks the winch into the gear system Solenoid Power from the vehicle battery flows through the weather sealed switch before being directed to the winch motor 10 Remote Switch The Power switch leads have a dual switch for po
10. djusted the braking angle or replaces the new brake slice WARNING Adjustment braking angle method The spring according to the spring gyrotropic pre tight two weeks then shows the spline tooth set according to following braking cutaway view the adjustment angle for 20 5 WINCH ASSEMBLY DRAWING 8 x o 44 xx B5B Tm x5 Bx Sis INCH PARTS LIST 520000 Part Qty Description Remark 1 52000001 4 25 2 52000002 4 Lock Washer 3 52000100 1 Motor Assembly 4 52000003 6 10 30 5 52000004 6 Lock Washer 10 6 52000005 1 Motor Bracket 7 52000006 2 Bushing Drum 8 52000200 1 Break shift Assembly 9 52000300 1 Drum Assembly 10 52000007 1 Screw M8 x 10 11 52000008 3 Tie Bar 12 52000009 10 Screw 8 70 13 52000010 10 Lock Washer 14 52000011 1 End Bearing 15 52000012 2 16 52000013 1 Gear Ring Output 17 52000400 1 Gear Carrier Assembly Output 18 52000014 1 Circlip For Hole 19 52000500 1 Gear Carrier Assembly Intermed
11. eads as detailed below Wireless switch receiver Black long wire assembly connect gt White wire connect relay 7137 BI the earthing terminal on the motor Yellow wire connect relay J1 T0 Connecting piece _7 Blue wire antenna connect Motor F2 7 wire connect relay J Black wire connect relay J2 Connecting piece 7 A 2 connect Motor F1 lt lt Connecting piece Black wire assembly connect motor s 2 connect motor A earthing terminal and battery negative Red long wire assembly B m U connect battery positive i Motor p Outlet ti Cy en Double color wire connect relay J3 Blue wire connect relay J 9 Brow wire connect relay J1 WMoter s earthing terminal CAUTION Batteries contain gases which are flammable and explosive Wear eye protection during installation and remove all jewelry Do not lean over battery while making connections 5 Assemble the clevis hook to the cable Take off the pin from the clevis hook connect the clevis hook to the cable and mount the pin back to the clevis hook 6 Always use the hand saver when free spooling and re spooling the wire Using the hand saver keeps your hands and fingers away from the rotating drum 7 Check for proper drum rotation Pull and turn the clutch knob to the C
12. ehind the vehicle or anchor point o Begin winching Be sure that the wire rope is winding evenly and tightly around the drum The vehicle that is being winched can be slowly driven to add assistance to the winching process Avoid shock loads keep the wire rope under tension p The vehicle to be winched should be placed in neutral and the emergency brake released Only release the brake pedal when under full tension Avoid shock loads to the winch This can damage the winch rope and vehicle q The winch is meant for intermittent use Under full load with a single line rig do not power in for more than a minute without letting the motor cool down for a few minutes and then resume the winching operation r The winching operation is complete once the vehicle is on stable ground and is able to drive under its own power s Secure the vehicle Be sure to set the brakes and place the vehicle in park t Release the tension on the wire rope The winch is not meant to hold the vehicle for long periods of time u Disconnect the wire rope from the anchor v Rewind the wire rope Make sure that any wire already on the drum has spooled tightly and neatly If not draw out the wire and re spool from the point where the rope is tight w Keep your hands clear of the winch drum and fairlead as the wire rope is being drawn in x Secure the hook and hook strap y Disconnect the remote control and store in a clean dry place 2 Clean and inspect c
13. factory No internal lubrication is required 1 ROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION mot Insert switch assembly all the way into the propery connector Loose battery cable Tighten nuts on all cable connections connections i does Defective switch Replace switch assembly assembly Check for voltage at armature port with Switch Defective motor pressed If voltage is present replace motor Water has entered Allow to drain and dry Run in short bursts without load until completely dry motor Motor runs but Turn clutch to the In position If problem cable drum does not turn Clutch not engaged persists a qualified technician needs to check and repair Motor runs slowly or without normal power Insufficient current or voltage Battery weak recharge Run winch with vehicle motor running Loose or corroded battery cable connections Clean tighten or replace Motor overheating Winch too long running time Allow winch to cool down periodically Motor runs in one direction only Defective switch assembly Loose or corroded battery cable or motor cable connections Clean and tighten Repair or replace switch assembly Winch braking malfunction Winch working wrong direction Brake slice worn or worn not Change winch working direction looking is to clockwise look at the motor end Simply rea
14. h as 50 When doubling the line back to the vehicle attach to the frame or other load bearing part The vehicle engine should be kept running during operation of the winch to minimize battery drain and maximize power and speed of the winch If the winch is used for a considerable amount of time with the engine off the battery may be drained and too weak to restart the engine Get to know your winch before you actually need to use it We recommend that you set up a few test runs to familiarize yourself with rigging techniques the sounds your winch makes under various loads the way the cable spools on the drum etc Inspect the wire rope and equipment before each use A frayed or damaged rope must be replaced immediately Use only the manufacturer s identical replacement rope with the exact specifications Inspect the winch installation and bolts to ensure that all bolts are tight before each operation Never connect the cable back to itself This will cause cable damage Always use a snatch block sling or chain of suitable strength as shown in the illustrations Store the remote control inside your vehicle in a place that it will not be damaged Any winch that appears to be damaged in any way is found to be worn or operates abnormally shall be removed from service Pull only on parts of the vehicle as specified by the vehicle manufacturer Only attachments and or adapters supplied by the manufacturer shall be used
15. iate 20 52000015 1 Gear Ring Intermediate 21 52000600 1 Gear Carrier Assembly Input 22 52000016 1 Gear lnput Sun 23 52000017 1 Shaft Sleeve 24 52000018 1 Trust Washer 25 52000700 1 Clutch Assembly 26 52000019 1 Gear Housing 27 2000020 8 Screw M1230 28 52000021 8 Lock Washer 212 29 52000022 2 Screw 10 35 30 52000004 2 Lock Washer 210 31 52000800 1 Roller Fairlead 32 52000900 1 Remote Control Switch RC3 33 52001000 1 Cable Assembly 34 52000023 1 Strap 35 52000024 1 Mounting Play 36 52000025 1 Connecting Piece 37 52000026 1 Connecting Piece 38 52001100 1 Relay With Screw Assembly 39 52001200 1 Cover With Screw Assembly 40 52000027 1 Connecting Piece 41 52000028 4 Connecting Block 42 52000029 2 Connecting Rod Sets 43 52001300 1 Battery Switch SPECIFICATION Rated line pull 20000 105 9072 kgs 12V Input 5 4kW 7 1hp Output 2 9 kW 3 9hp 9 WOUNG 24V Input 6 0kW 7 9hp Output 3 1 kW 4 1hp Gear reduction ratio 430 1 Cable Dia X L 015 32 X87 O12mm x 26 5m Drum size Dia X L 3 5 X8 5 89mm X 217mm Mounting bolt pattern 10 x4 5 254mm X 114 3mm 10 x 6 5 254mm 165 1mm 8 M12 Overall dimensions 24 0 X 8 4 X 10 9 LXWXH 610mm X214mm x276mm Net weight 158 7 72 0 Ibs kg Pull Speed Amperes Volts First layer Line Pull Line Speed ft min m min Current A Ibs kgs 12V DC M
16. onnections and mounting hardware for next winching operation WINCH ASSEMBLY AND MOUNTING 1 Your 2000010 winch is designed with a bolt pattern that is standard in this class of winch Many winch mounting kits are available that utilize this bolt pattern for the popular vehicles and mounting channels If you will utilize the mounting channel you must ensure that it is mounted on a flat surface so that the three major sections motor drum and gear housing are properly aligned Proper alignment of the winch will allow even distribution of the full rated load 2 f your winch choices the mounting channel Start by connecting the roller fairlead Parti 52000800 to the mounting channel using 2 each of the cap screw M10 X 35 Part 52000022 lock washer Part 52000004 and securing Make sure the screw is placed through the mounting channel and roller fairlead from inside the channel This will allow enough clearance for the winch to be placed in the channel without obstruction 3 Assemble the winch to the mounting channel or vehicle bump base by first pulling and releasing the clutch knob to the CLUTCH OUT position free spooling Pull out a few inches of cable from the drum and feed the wire loop through the opening in the front of the mounting channel and roller fairlead Now using the remaining M12 x 30 cap screws Partt 52000020 and lock washer Part 52000021 secure the winch to the mounting channel 4 Connect the winch motor l
17. ps before reversing directions When the pulling is complete remove the switch assembly Part 52000900 From the female connector of the directional valve and replace the female connectors cover REPLACING THE WIRE ROPE If the wire rope has become worn or is beginning to show signs of strands breaking it must be replaced before being used again 1 2 Turning clutch to the CLUTCH OUT position Extend cable assembly to its full length Note how the existing cable is connected to the drum Remove old cable assembly and attach new one as the old cable connected to the drum Insert the end of the new and secure the screw M8x10 Part S2000007 Ensure that the new cable wraps in the same rotation direction as the old one The cable should leave the drum from the bottom under the drum Turning clutch to the CLUTCH IN position Retract Cable Assembly onto drum first five wraps being careful not to allow kinking then winch cable must be wound onto the drum under a load of at least 1096 rated line pull A WARNING Only replace the wire rope with the identical replacement part recommended by the manufacturer MAINTENANCE Periodically check the tightness of mounting bolts and electrical connections Remove all dirt or corrosion and always keep clean Do not attempt to disassemble the gear box The gearbox has been lubricated using a high temperature lithium grease and is sealed at the
18. wering in or powering out your winch drum The Power switch leads allow you to stand clear of the wire rope when the winch is under load 11 Wireless Remote Control allow you control winch up to 50 Ft away 12 Universal Flat Bed Mounting Channel Your winch could have been optionally supplied with a flat bed mounting channel that can be mounted to most flat surfaces such as trailers step bumpers truck beds etc The mounting channel also has holes to accept your roller fairlead 13 Snatch Block If Your winch is supplied with a snatch block that can double the pulling power of the winch or change the pulling direction without damaging the wire rope We recommend you to use double line and snatch block for pulling over 7096 of the rated line pull SAFETY PRECAUTIONS AXWARNING AA A WARNING Do not exceed rated capacity shown in this table Layer Rated line pull Ibs kgs Total rope on the drum ft m 1 20000 9072 18 0 6 0 2 16160 7330 40 7 13 0 3 13557 6149 65 9 21 0 4 11677 5297 86 9 26 5 AA WARNING Intermittent use only Allow winch to cool between uses A WARNING Do not use winch to lift vertically A WARNING Do not use winch to pull or move people in any way WARNING NEVER cut weld or modify any part of the winch or cable ANWARNING A minimum of five wraps of cable around the drum barrel is necessary for pulling and holding the rated load AXWARNI
Download Pdf Manuals
Related Search