Detail K2 S12000-SR Use and Care Manual
Contents
1. 7 Always use the Hand Saver when free spooling and re spooling the wire rope Using the Hand Saver keeps your hands and fingers away from the rotating drum 8 Check for proper drum rotation Pull and turn the clutch knob to the off position Free spooling Pull out some cable from the drum and then turn the clutch knob to the 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 SAFETY PRECAUTIONS WARNING WARNING DO NOT EXCEED RATED CAPACITY AXWARNING Intermittent use only WARNING Do not use winch in lifting or moving or persons AXWARNING A minimum of five wraps of cable around the drum barrel is necessary for pulling and holding the rated load The cable clamp is not designed to hold the load without 5 wraps of cable around the barrel A WARNING Keep yourself and others a safe distance to the side of the cable when under tension A WARNING 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 WARNING Never step over a cable or near a cable under load WARNING Don t move the vehicle to pull a load towing on the winch cable This could result in cable breakage WARNING2. Defective Switch Loose or corroded battery cable or motor direction only Assembly cable connections Clean and tighten Repair or replace switch assembly 12 INCH ASSEMBLY DRAWING WINCH PARTS LIST C12000EWX Part Qty Description Remark 120001 1 Terminal Protect 14 2 120100 1 Motor Assembly 3 120002 6 Cap Screw M10 x 35 4 120003 6 Lock Washer 010 5 120004 6 Think Flat Washer 010 6 120005 6 HeX Flange Nut M10 7 120200 1 Break Shaft Assembly 8 120006 2 Bushing Drum 9 120007 2 Tie Bar 10 120008 1 Cap Screw M6 x 10 11 120009 4 Think Flat Washer 08 12 120010 4 Cap Screw M8 x 30 13 120300 1 Drum Assembly 14 120011 10 Screw M4 x 25 15 120012 10 Lock Washer 04 16 120013 1 End Bearing 17 120014 1 Gasket 18 120015 1 Gear Ring 19 120400 1 Gear Carrier Assembly Input 20 120500 1 Gear Carrier Assembly Intermediate 21 120600 1 Gear Carrier Assembly Output 22 120016 1 Gear Input Sun 23 120017 1 Trust Washer 24 120018 1 Gear Housing 25 120019 1 Clutch Screw 26 120020 1 Ring Seals 27 120021 1 Clutch Cover 28 120022 1 Clutch 29 120030 2 Heel Block 30 120700 1 Control Box
3. 31 120031 2 Screw M5 x 2 2 32 120032 2 Lock Washer 5 33 120RS 1 Remote Control Switch R3 34 120800 1 Cable Assembly 35 120WRS 1 Wireless Remote Control Switch 36 120900 1 Roller Fairlead Rated line pulls C12000EWX SPECIFICATION 12000 Ibs 5443Kgs 15 Gear reduction ratio Motor Overall dimensions 230 1 12V 24V Series Wound Input Power 6 5 hp 4 6KW 22 8 L x6 30 W x9 00 H 579 L mm X 160 W mm X 229 H mm Drum size 2 48 D x 8 8 L 63 D mm x223 L mm Cable 13 32 D x 83 7 L 10 2mm D x 25 5m L Weight 40kgs DUTY CYCLE Line speed and motor current First layer Line speed Motor current Line pall ft min m min Amps Max Ib kN 12V DC 12V DC 0 22 6 6 65 6000 26 67 11 15 3 4 120 8000 35 56 7 22 2 2 230 10000 44 45 4 92 1 5 310 12000 53 34 3 28 1 0 380 Line pull and cable capacity Layer of cable Rated ge a Layer Cable E per Layer 1 12000 53 34 15 1 4 6 2 9533 42 38 34 1 10 4 3 7907 35 15 57 7 17 6 4 6755 30 03 83 7 25 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
4. Disconnect the remote control and battery leads when not in use WARNING Do not exceed maximum pull rating Avoid shock loads by using the control switch intermittently to take up the 6 slack in the wire rope Shock loads can far exceed the rate capacity for the wire rope and drum XWARNING Do not exceeds maximum line pull ratings shown on the tables WARNING 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 re spool correctly and while wearing gloves 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 Do not use as a hoist Do not use for overhead lifting Failure to heed these warnings may result in personal injury and or property damage AXWARNING 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 No modifications
5. below Distributor Date of Purchase Invoice No Serial No In the unlikely event you experience problems contact the distributor with this information 17
6. release the rope 2 Insert the end of the new rope and secure the M6 x 10 mm bolt tightly 3 Engage the clutch and re spool the new rope on the drum keeping tension on the rope as it spools Ensure that the rope is respooling in the under wind position A WARNING Only replace the wire rope with the identical replacement part recommended by the manufacturer TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION Motor does not turn on Switch Assembly not connected properly Loose battery cable connections Defective Switch Assembly Defective motor Water has entered motor Insert Switch Assembly all the way into the connector Tighten nuts on all cable connections Replace Switch Assembly Check for voltage at armature port with Switch pressed If voltage is present replace motor Allow to drain and dry Run in short bursts without load until completely dry Motor runs but cable drum does not turn Clutch not engaged Turn clutch to the In position If problem 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 running time too Allow winch to cool down periodically long Motor runs in one
7. to be placed in the channel without obstruction 3 Assemble the winch to the Mounting Channel Part 121000 by first pulling and releasing the clutch knob to Off 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 M10 x 35 Cap Bolts Part 120002 Flat Washer Part 120004 Lock Washer Part 120003 and M10 Nut Part 120005 secure the winch to the mounting channel 4 Connect the battery and motor leads as the drawing above every type of winch is different each other 5 Connect the winch motor leads as detailed below Blue wire connect motor A Yellow wire connect Motor F1 Red wire connect Motor F2 Red long wire assembly connect battery positive Black long wire assembly connect the earthing terminal on the motor Black wire assembly connect motor s earthing terminal and battery negative Ce m a A e I Motor pa ah D ay lello FL le Moter 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 6 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
8. 12000LB ELECTRIC WINCH Assembly amp Operating Instructions INTRODUCTION Congratulations on your purchase of a high quality Winch We design and build winches to strict specifications and with proper use and maintenance should bring you years of satisfying service WARNING Read study and follow all instructions before operating this device 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 C AUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This notation is also used to alert against unsafe practices Indicates a potentially hazardous situation which if not avoided A WARNING could result in death or serious injury INCLUDED WITH YOUR WINCH DESCRIPTION 1 9 o NDOA MN Winch Assembly with Wire Rope Cap Bolt M10 Xx 35 Lock Washer 10 Thinck Flat Washer 10 Hex Flange Nut M10 Clevis Hook w Pin Control box of 12000 Supplied for Prototype Control box of 12000 S Supplied for S Type Power Switch suppl
9. alterations or deviation to the winch are authorized by the manufacturer and SHALL not be made 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 AXCAUTION If the motor stalls do not maintain power to the 7 winch Electric winches are designed and made of intermittent use and should not be used in constant duty applications A CAUTION Never release the free spool clutch when there is a load on the winch AXCAUTION Use hand saver hook when handling the hook for spooling or un spooling the wire rope GENERAL TIPS FOR SAFE OPERATION The C12000 and its all derivative types are rated at 12000 lbs capacity when spooling the first rope layer on the drum Overloads can damage the winch motor or wire rope For loads over 10000 lbs we recommend the use of the pulley block snatch block to double the wire rope line The 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 much 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 time with the engin
10. e 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 shall be replaced immediately Use only manufacturers 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 UNTIL REPAIRED Iit is recommended that the 8 necessary repairs be made by a manufacturer s authorized repair facility Pull only on areas of the vehicle as specified by the vehicle manufacturer e Only attachments and or adapters supplied by the manufacturer shall be used Self Recovery ry Pj Loft om WI o WIA MM wont wrong Fig 3 2 A Single Line Double Line Fig 3 4 RIGGING TECHNIQUES Locate a suitable anchor such as a strong tree tru
11. ied by your choice 9 1 R1 Remote control 9 2 R2 Remote control 9 3 R3 Remote control 9 4 Wireless Remote Control THE FOLLOWING DESCRIPTIONS ARE OPTIONAL 001 Snatch Block Pulley 002 Roller Fairlead and Screws 003 Mounting Channel 004 SWR Tensioner 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 15000lbs QUANTITY 1 4 4 4 4 Heavy Blanket place on the cable to absorb energy should the wire rope break GETTING TO KNOW YOUR WINCH Your 12000lb 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 Practices using your winch before you are in a situation to need to use it 1 Motor Your 6 5hp motor is powered by a 12 24 volt battery and provides power to the gear mechanism which turns the drum and winds the wire rope 2 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 3 Wire Rope Your winch has a 13 32 X83 7 galvanized aircraft cable designed specifically for load capacity of 12000lbs The wire rope feeds onto the drum
12. in the under wind position through the roller fairlead and is looped at the end to accept the clevis hook pin 4 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 5 Mechanic Gear System The reduction gears convert the winch motor power into extreme pulling forces 6 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 The braking action is applied by a separate mechanical brake 7 Free Spooling Clutch The clutch allows the operator to manually disengage Out the spooling drum from the gear train free spool Engaging the clutch In locks the winch into the gear system 8 Solenoid Power from the vehicle battery flows through the weather sealed switch before being directed to the winch motor 9 Remote Switch The Power switch lead has a dual switch for powering 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 3 10 Wireless Remote Control allow you control winch far from 50 Ft away 11 Universal Flat Bed Mounting Channel Your winch has been optional 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 als
13. nk or boulder Always use a sling as an anchor point ACAUTION Do not attach the clevis hook back onto the cable as this could cause damage to the cable As shown in Fig 3 1 4 Do not winch from an acute angle as the 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 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 10000lbs 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 approximately 50 A WARNING Never use your winch for overhead hoisting or for lifting people or moving people 9 INCHING 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 also save battery power 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 wi
14. o has holes to accept your roller fairlead 12 Snatch Block If Your winch were supplied with a snatch block that used properly can double the pulling power of winch or change your pulling direction without damaging the wire rope We recommend you to use double line and snatch block for pulling over 85 related line pull WINCH ASSEMBLY AND MOUNTING 12000lbs Red Battery Black Battery Switch Wireless Remote Control 1 Your 12000lb winch is designed with a bolt pattern that E standard in this class of winch Many winch mounting kits are available that utilize this bolt pattern for the most popular vehicle and mounting channels If you cannot find a kit locally contact us and we will provide you with the name of a dealer near you 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 Start by connecting the Roller Fairlead Part 12900 to the Mounting Channel Part 121000 using 2 each of the Cap Bolt M10 X 35 Part 120002 Flat Washer Part 120004 Lock Washer Part 120003 and securing with M10 Nut Part 120005 Make sure the bolt is placed through the mounting channel and roller fairlead from inside the channel This will allow enough clearance for the winch
15. re rope g Engage the clutch h Connect the remote control to the winch i Start your engine to ensure power is being replenished to the battery j 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 for added protection n Clear the area Make sure all spectators all well back and that no one is directly in front or behind 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 10 r The winching operation i
16. s 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 z Clean and inspect connections and mounting hardware for next winching operation MAINTENANCE 1 Periodically check the tightness of mounting bolts and electrical connections Remove all dirt or corrosion and always keep clean 2 Do not attempt to disassemble the gear box Repairs should be done by the manufacturer or an authorized repair center 3 The gear box has been lubricated using a high temperature lithium grease and is sealed at the factory No internal lubrication is required REPLACING THE WIRE ROPE 1 If the wire rope has become worn or is beginning to show signs of strands breaking it must be replaced before being used again To do this remove the defective rope by free spooling Remove the bolt Part 120008 M6x10 on the drum and
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