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I N S T A L L A T I O N
DO NOT operate
WARNING
!
this winch out-
doors or in a corrosive or explosive
environment.
MINIMUM ELECTRICAL
REQUIREMENTS
The three-prong plug must be plugged
into a 115 Volt, AC grounded outlet
equipped with a ground fault inter-
rupter (GFI). Do not plug into an
ungrounded outlet by using a three
prong adapter. Make sure that the
power supply cords and reversing switch
are positioned so that the moving load
will not damage them. Unplug the
winch when not in use. Electrical storms
or line surges can cause premature fail-
ure of the internal bridge rectifier.
Failure to
WARNING
!
ground this
winch could result in a fatal
electric shock.
Step (1)
Install mounting kit or structural support
for winch.
Step (2)
Mount the winch to the mount that you
have designed.
Mounting bolts supplied are the correct
length for use with up to a 1/4" (6.3mm)
thick plate.
Do not
WARNING
!
substitute
any strength grade weaker than
grade 5.
Step (3)
Lift the freespool clutch lever to the
"Free" position. Pull several feet of wire
rope off the drum. Return the clutch
lever back to the "Engaged" position.
The switch
CAUTION
!
assembly must
be kept free of dirt and moisture
to ensure safe operation.
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OPERATION
This unit is activated via the switch
at the end of the six foot cord. To
remove wire rope from the winch,
depress the "Rope Out" direction. The load
will stop without coasting when the
switch is released. To pull a load or
spool wire rope onto the drum,
s
depress the "Rope In" direction.
ee Figure 9
for winch markings.Your winch is
designed to pull 1,000 pounds in single
line for 20 seconds "On" time on the
wire rope layer closest to the drum.
Attempts to pull more than this
weight or exceed the duty cycle may
cause damage to the winch or wire
rope and could cause the circuit break-
er to trip, and the winch will not oper-
ate. (See "Trouble Shooting".)
Maintain a minimum of five wraps
of wire rope around the winch drum
before attempting any pulls.
ROPE IN
Figure 9
ROPE OUT
PULLING OUT THE WIRE ROPE
A part of your winch that will require
periodic attention and eventural replacement
is the wire rope. Inspect the wire rope
frequently.
If fraying exists, replace the wire rope at once.
Your winch uses galvanized aircraft type 7 x 19
cable. Always replace the wire rope with
Superwich replacement rope. Because all rope
is subject to wear, it is excluded from our
warranty.
The wire rope has been installed on
your winch under minimal load at the
factory. The wire rope must be
respooled onto the drum under load
so that the outer layers will not draw
down into the inner ones thereby
damaging the wire rope.
Lift the clutch lever to the "Free " posi-
tion as shown in Figure 16. If there is
a load on the wire rope, the clutch
lever may not turn easily. DO NOT
FORCE THE CLUTCH LEVER. Release
tension on the wire rope by jogging
out some of the wire rope. Release
the clutch and pull out the wire rope
and secure to anchor or load. Check
that there are at least five (5) turns of
wire rope left on the drum. Re-
engage the drum by returning the
clutch lever to the "Engaged" posi-
tion (see Figure 16).
Lever must be in
WARNING
!
the "Engaged"
position and locked before
.
winching
Figure 16
TIPS FOR EXTENDING THE LIFE OF
YOUR WINCH
1. KEEP A TIGHTLY WOUND WIRE
ROPE DRUM. Do not allow the
wire rope to become loosely
wound. A loosely-wound spool
allows a wire rope under load to
work its way down into the layers
of wire rope on the drum. When
this happens, the wire rope may
become wedged within the body
of the windings damaging the
wire rope. To prevent this prob-
lem, keep the wire rope tightly
and evenly wound on the drum
at all times. A good practice is to
rewind the wire rope under ten-
sion after each use.
2 . DO NOT ALLOW WINCH MOTOR
TO OVERHEAT. Remember, the
winch is for intermittent use only.
During long or heavy pulls the
motor will get hot. At 1,000 lb.
(454 kg) allow motor to cool after
20 seconds of "On" time. At loads
less than 500 lb. (227 kg) allow to
cool after 2 minutes of "On" time.
3 . USE A PULLEY BLOCK FOR HEAVY
LOADS. To maximize winch and
wire rope life, use a pulley block
to double line heavier loads
(Figure 17).
Figure 17
4. The pull required to start a load
moving is often much greater
than the pull required to keep it
moving. AVOID FREQUENT STOPS
AND STARTS during pull.
5. PREVENT KINKS BEFORE THEY
OCCUR.
a
b
c
Figure 18
a. This is the start of a kink. At
this time, the wire rope should
be straightened.
b. The wire rope was pulled and
the loop has tightened to a
kink. The wire rope is now per-
manently damaged and must
be replaced.
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