Superwinch S3000 Manuals

O W N E R ’ S M A N U A L INSTALLATION • OPERATION • MAINTENANCE SAFETY PRECAUTIONS • REPAIR PARTS S3000, S4000, S5000 12 & 24 Volt DC Electric Winches With Remote Control READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF YOUR SUPERWINCH PRODUCT. Ratings assume a 10% coefficient of friction. * A 10% slope is a rise of one foot in ten feet. Slope in approximate degrees is also shown above. ** All loads shown are for single-line operation. Double-line operation with optional pulley block (see Figure 2) approximately doubles capacity of winch. Figure 1 Freespool Clutch In-Drum Brake Remote Switch Receptacle Permanent Magnet Motor GENERAL DESCRIPTION Integrated Solenoids 3 2 Thank you for purchasing an S series winch from Superwinch. It has been designed and manufactured to provide years of trouble-free operation. We hope you will be pleased with its performance. When requesting information or ordering replacement parts; always give the following information: 1. Winch Part Number 2. Serial Number (found on housing) 3. Part Number (found in Replacement Parts List section) 4. Part Description Please read and understand this Owner’s Manual before installing your winch. Pay particular attention to the General Safety Information. Your winch is a very powerful machine. If used unsafely or improperly, there is a possibility that property damage or personal injury could result. We have included several features in the winch to minimize this possibility; however, your safety ultimately depends on your caution when using this product. Throughout this manual, you will find notations with the following headings: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. 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. Note: Indicates additional information in the installation and operation procedures of your winch. Correct installation of your winch is a requirement for proper operation. Please Note: The Superwinch S series winch is designed primarily for intermittent duty general use. This winch is not designed to be used in industrial or hoisting applications and Superwinch does not warrant it to be suitable for such use. Superwinch manufactures a separate line of winches for industrial/commercial use. Please contact our Customer Service Department for further information. Congratulations on your choice! I N T R O D U C T I O N CAUTION ! Roller Fairlead Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º) Lbs.** kg** 12,563 5,698 8,503 3,857 6,527 2,961 3,213 1,457 ROLLING LOAD CAPACITIES S3000 Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 lb. (1361 kg) Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/16" x 60' Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 1.3 hp (0.97 kW) peak Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1 S4000 Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,000 lb. (1814 kg) Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/32" x 60' Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 1.8 hp (1.34 kW) peak Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1 S5000 Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,000 lb. (2268 kg) Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4" x 50' Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 2.1 hp (1.57 kW) peak Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1 * Based on first layer performance S P E C I F I C AT I O N S S5000 S4000 S3000 Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º) Lbs.** kg** 17,588 7,978 11,905 5,400 9,138 4,145 4,499 2,041 Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º) Lbs.** kg** 22,613 10,257 15,306 6,943 11,749 5,329 5,784 2,624 Description Quantity Winch assembly with wire rope including lead wires 1 Circuit breaker assembly with hardware 1 Handsaver 1 Mounting hardware kit 1 Remote pendant 1 Owner’s manual 1 This carton contains the following items. Please unpack carefully. Read instructions before beginning. U N PA C K I N G D I M E N S I O N S S3000, S4000, S5000 Figure 2 P E R F O R M A N C E Wire Rope Max. Pulling Capacity Layer lbs. kg 1 3,000 1364 2 2,250 1021 3 2,000 907 4 1,750 794 Motor Load Speed Current lbs. kg ft/min m/min Amps 0 0 17.0 5.1 15 1,000 454 12.5 3.8 70 2,000 907 9.0 2.7 117 2,500 1134 7.5 2.3 155 3,000 1361 4.5 1.4 220 S3000 Wire Rope Max. Pulling Capacity Layer lbs. kg 1 4,000 1818 2 3,000 1361 3 2,600 1179 4 2,000 998 Motor Load Speed Current lbs. kg ft/min m/min Amps 0 0 21.6 6.5 30 1,000 454 16.0 4.8 90 2,000 907 12.4 3.8 155 2,500 1134 10.6 3.2 180 3,000 1361 8.8 2.7 215 3,500 1589 6.2 1.9 250 4,000 1814 4.5 1.4 311 Wire Rope Max. Pulling Capacity Layer lbs. kg 1 5,000 2273 2 4,000 1814 3 3,500 1588 4 2,900 1315 Motor Load Speed Current lbs. kg ft/min m/min Amps 0 0 17.5 5.9 36 1,000 454 14.5 4.6 80 2,000 907 12.0 3.4 135 3,000 1361 9.5 2.2 200 4,000 1814 7.3 1.3 265 5,000 2268 4.5 1.4 350 S4000 S5000 * Based on first layer performance NOTES 1. All dimensions are in inches [millimeters]. 2. Typical mount is to flat surface capable of handling the loads. Bolts to be Grade 5 or better. 6.0 (152) 15.1 (383) 7.2 (183) 7.1 (180) 3.1 (79) 5.9 (150) 3.69 (93.7) 1.24 (31.5) ROLLER FAIRLEAD SCREWS DRUM SUPPORT PLATE SCREWS MOTOR SCREWS 4 5 DRUM SUPPORT PLATE Your S series winch is a very powerful machine. Treat it with respect, use it with caution and always follow the safety guidelines. The wire rope may break before the winch stalls. For heavy loads, use a pulley block to reduce the load on the wire rope. 1. The S3000, S4000, and S5000 winch is rated at 3,000, 4,000, and 5,000 pounds (1361, 1814, 2268 kg) (single line) capacity on the wire rope layer closest to the drum. DO NOT OVERLOAD. DO NOT ATTEMPT PROLONGED PULLS AT HEAVY LOADS. Do not maintain power to the winch if the motor stalls. Overloads can damage the winch and/or the wire rope and create unsafe operating conditions. FOR LOADS OVER 2/3 RATED CAPACITY, WE RECOMMEND THE USE OF THE OPTIONAL PULLEY BLOCK TO DOUBLE LINE THE WIRE ROPE (Figures 3 & 18). This reduces the load on the winch and the strain on the wire rope by approximately 50%. If attaching back to vehicle, attach to the frame or other load bearing part. The vehicle engine should be running during winch operation to minimize battery drain and maximize winch power and speed. If considerable winching is performed with the engine off, the battery may be too weak to restart the engine. 2. AFTER READING AND UNDER- STANDING THIS MANUAL, LEARN TO USE YOUR WINCH. After installing the winch, practice using it so you will be familiar with it when the need arises. 3. DO NOT “move” your vehicle to assist the winch in pulling the load. The combination of the winch and vehicle pulling together could overload the wire rope and the winch. 4. KEEP WINCHING AREA CLEAR. Do not allow people to remain in the area during winching operations. ALWAYS STAND CLEAR OF WIRE ROPE, HOOK AND WINCH. IN THE UNLIKELY EVENT OF ANY COM- PONENT FAILURE, IT IS BEST TO BE OUT OF HARM‘S WAY. 5. INSPECT WIRE ROPE AND EQUIP- MENT FREQUENTLY. A FRAYED WIRE ROPE WITH BROKEN STRANDS SHOULD BE REPLACED IMMEDIATELY. Always replace wire rope with the manufacturer‘s identical replacement part (see Replacement Parts List). Periodically check the winch installation to ensure that all bolts are tight. 6. USE HEAVY LEATHER GLOVES when handling wire rope. DO NOT LET WIRE ROPE SLIDE THROUGH YOUR HANDS EVEN WHEN WEARING GLOVES. 7 G E N E R A L S A F E T Y I N F O R M AT I O N Figure 3 Single Line Double Line I N T E R M I T T E N T D U T Y An electric winch is like any other motor driven power tool such as an electric drill or saw. The electric motor should not be allowed to become excessively hot. Normal precautions will extend the life of your motor. Keep the duration of pulls as short as possible. If the end of the motor becomes uncomfortably hot to touch, stop winching and allow the motor to cool down. If the winch motor stalls, do not continue to apply power to the winch. 6 F E AT U R E S Electric Motor – 1.3 (S3000), 1.8 (S4000), 2.1 (S5000) peak hp (.97 (S3000), 1.34 (S4000), 1.57 (S5000) kW) 12V or 24Volt Permanent Magnet. Braking – A wrap spring brake which will hold 50% of rated load on the first wrap. Reducing by approximately 10% per layer thereafter. Drum – Die cast aluminum running in maintenance free bearings. Freespool Clutch – Operated by an easy action lever which disen- gages the gearbox to allow the wire rope to be pulled out without using electric power. A tension plate reduces backlash and snarling when pulling out the wire rope. Remote Switch – 30' (13.64 m) hand held pendant switch assembly with toggle switch. Mounting – Optional custom engineered mounting kits are available for vehicle frame attachment.

O W N E R ’ S M A N U A L INSTALLATION • OPERATION • MAINTENANCE SAFETY PRECAUTIONS • REPAIR PARTS S3000, S4000, S5000 12 & 24 Volt DC Electric Winches With Remote Control READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF YOUR SUPERWINCH PRODUCT. 89-12792 Rev - 1/30/04 Superwinch, Inc. Superwinch, Ltd. Winch Drive Abbey Rise, Whitchurch Road Putnam, CT 06260 Tavistock, Devon PL 19 9DR U.S.A. England Tel. (860) 928-7787 Tel. (1822) 614101 Fax (860) 963-0811 Fax (1822) 615204 VALABLE A TRAVERS LE MONDE GARANTIE LIMITÉE. Superwinch, Inc. (le “Vendeur”) garantit à l’acheteur d’origine (“vous”) que toutes les pièces et composants, à l’exception du câble métallique, sont sans vice de matériaux ou de fabrication, et ce, pendant une période d’un (1) an à compter de la date d’achat prouvable. Tout produit Superwinch défectueux sera réparé ou remplacé sans dépenses de votre part si vous respectez ces procédures. Les garanties énoncées par les présentes sont exclusives tiennent lieu de toutes autres garanties expresses ou implicites. PROCÉDURE DE RECOURS À LA GARANTIE LIMITEE. Dès découverte d’un produit Superwinch défectueux, vous devrez envoyer à Superwinch, à l’usine ou à un Centre de réparation autorisé par l’usine, une notification écrite dudit défaut et vous devrez envoyer par courrier ou autre service de livraison le Superwinch défectueux, port et frais postaux payés à l’avance. Les réparations ou remplacements par le Vendeur conformément à la présente Garantie s’effectueront normalement dans les quinze (15) jours ouvrables suivant récep- tion du Superwinch défectueux. Le Vendeur ou ses Agents autorisés peut facturer des frais raisonnables pour les pièces et la main d’oeuvre en cas de réparation non couverte par la présente Garantie limitée. LIMITATIONS ET EXCLUSIONS EN CE QUI CONCERNE LA GARANTIE ET LES REMÈDES. La réparation et/ou le remplacement de tout Superwinch défectueux ou de tout composant d’un tel Superwinch tel que convenu par les présentes est votre remède exclusif. Les exclusions et limita- tions de garanties et les limitations de REMEDES ci-dessous seront expressément applicables : A. Garanties expresses . Le Vendeur garantit que le Superwinch est tel qu’il est décrit dans le “Mode d’emploi Superwinch” fourni avec la présente; aucune autre garantie expresse n’est don- née en ce qui concerne le Superwinch. Si un modèle ou échantillon vous a été montRé, ledit mod- èle ou échantillon a été utilisé à des fins d’illustration uniquement et ne sera pas considéré une garantie que le Superwinch sera conforme au modèle ou à l’échantillon. LE VENDEUR NE DONNE AUCUNE GARANTIE EXPRESSE EN CE QUI CONCERNE LE CABLE MÉTALLIQUE INCORPORÉ AU PRO- DUIT. B. Garantie implicite . LA GARANTIE IMPLICITE DE L’APTITUDE À LA VENTE ET TOUTE AUTRE GARANTIE IMPLICITE S’APPLIQUERA UNIQUEMENT POUR UNE DURÉE D’UN (1) AN À COMPTER DE LA DATE D’ACHAT PROUVABLE. LE CABLE MÉTALLIQUE EST VENDU “TEL QUEL” SANS AUTRE GARANTIE IMPLICITE. CERTAINS ÉTATS AMÉRICAINS NE PERMETTENT PAS DE LIMITER LA DURÉE DES GARANTIES IMPLICITES; IL EST DONC POSSIBLE QUE LA LIMITATION CI-DESSUS NE S’APPLIQUE PAS À VOTRE CAS. C. Dommages indirects. SUJET AUX OBLIGATIONS DE LA GARANTIE LIMITÉE DU VENDEUR ÉNONCÉES DANS LE PRÉSENT DOCUMENT, LE VENDEUR NE SERA AUCUNEMENT RESPONSABLE DE DOMMAGES INDIRECTS, DE QUELQUE NATURE QUE CE SOIT, NI DE DOMMAGES INDIRECTS À LA PROPRIÉTÉ, NI DE PERTES DE PROFITS, NI DE PERTES D’UTILISATION POUVANT SURVENIR À CAUSE D’UN DÉFAUT, D’UN MAUVAIS FONCTIONNEMENT OU D’UNE PANNE QUELCONQUE DU SUPER- WINCH CI-JOINT. CERTAINS ÉTATS AMÉRICAINS NE PERMETTENT PAS D’EXCLURE OU DE LIMITER LES DOMMAGES INDIRECTS; IL EST DONC POSSIBLE QUE LA LIMITATION CI-DESSUS NE S’APPLIQUE PAS À VOTRE CAS. D. Condition de la garantie. Le Vendeur ne sera pas tenu de se conformer aux obligations de garantie fournies par les présentes si la cause du défaut, du mauvais fonctionnement ou de la panne du Superwinch est un dommage (ne résultant pas de composants défectueux ou qui fonc- tionnent mal) ou une utilisation déraisonnable par vous. Le terme Utilisation déraisonnable com- prend mais ne est pas limité au manquement à la maintenance, à l’installation et à l’utilisation raisonnables et nécessaires conformément aux consignes contenues dans le Mode d’emploi Superwinch, et à l’utilisation du Superwinch pour des charges supérieures à celle figurant dans le Mode d’emploi pour le modèle en question. La responsabilité du Vendeur sous la présente garantie ou pour toute perte du produit Superwinch ou dommage à celui-ci ne dépassera pas le coût de correction des défauts du produit Superwinch ou de remplacement de celui-ci, et lors de l’expiration de la période de garantie, toute telle responsabilité prendra fin. Les agents, distribu- teurs et employés du Vendeur ne sont pas autorisés à modifier la présente garantie ni à donner d’autres garanties complémentaires obligatoires pour le Vendeur. Toute déclaration supplémen- taire, qu’elle soit écrite ou orale, ne constituera donc pas une garantie et ne devra pas être consid- érée comme valable. REMEDES LÉGAUX DE L’ACHETEUR. Cette garantie limitée vous donne des droits légaux spéci- fiques et il est possible que vous ayez d’autres droits qui varient d’un état à l’autre aux Etats-Unis et d’un pays à l’autre. Vous avez également des droits de garantie implicite. En cas de problème avec le service ou la performance suivant la garantie limitée, il est possible que vous puissiez inten- ter une action en justice devant la Cour des Prudhommes (“small claims court”), devant le tribunal d’état ou devant le tribunal fédéral des Etats-Unis ou dans une autre juridiction appropriée en dehors des Etats-Unis. QUESTIONS. Toute question en ce qui concerne le respect des garanties énoncées dans les présentes doit être envoyée, par écrit, à : Superwinch, Inc., Winch Drive, Putnam, CT 08260 U.S.A. ou à Superwinch Limited, Abbey Rise, Whitchurch Road, Tavistock, Devon PL 19 9DR, England G A R A N T I E L I M I T É E Ratings assume a 10% coefficient of friction. * A 10% slope is a rise of one foot in ten feet. Slope in approximate degrees is also shown above. ** All loads shown are for single-line operation. Double-line operation with optional pulley block (see Figure 2) approximately doubles capacity of winch. Figure 1 Freespool Clutch In-Drum Brake Remote Switch Receptacle Permanent Magnet Motor GENERAL DESCRIPTION Integrated Solenoids 3 2 Thank you for purchasing an S series winch from Superwinch. It has been designed and manufactured to provide years of trouble-free operation. We hope you will be pleased with its performance. If you are not, for any reason, please contact our Customer Service Department: (860) 928-7787 USA; (1822) 614101 England. When requesting information or ordering replacement parts; always give the following information: 1. Winch Part Number 2. Serial Number (found on housing) 3. Part Number (found in Replacement Parts List section) 4. Part Description Please read and understand this Owner’s Manual before installing your winch. Pay particular attention to the General Safety Information. Your winch is a very powerful machine. If used unsafely or improperly, there is a possibility that property damage or personal injury could result. We have included several features in the winch to minimize this possibility; however, your safety ultimately depends on your caution when using this product. Throughout this manual, you will find notations with the following headings: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. 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. Note: Indicates additional information in the installation and operation procedures of your winch. Correct installation of your winch is a requirement for proper operation. Please Note: The Superwinch S series winch is designed primarily for intermittent duty general use. This winch is not designed to be used in industrial or hoisting applications and Superwinch does not warrant it to be suitable for such use. Superwinch manufactures a separate line of winches for industrial/commercial use. Please contact our Customer Service Department for further information. Congratulations on your choice! I N T R O D U C T I O N CAUTION ! Roller Fairlead Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º) Lbs.** kg** 12,563 5,698 8,503 3,857 6,527 2,961 3,213 1,457 ROLLING LOAD CAPACITIES S3000 Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 lb. (1361 kg) Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/16" x 60' Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 1.3 hp (0.97 kW) peak Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1 S4000 Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,000 lb. (1814 kg) Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/32" x 60' Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 1.8 hp (1.34 kW) peak Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1 S5000 Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,000 lb. (2268 kg) Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4" x 50' Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 2.1 hp (1.57 kW) peak Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1 * Based on first layer performance S P E C I F I C AT I O N S S5000 S4000 S3000 Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º) Lbs.** kg** 17,588 7,978 11,905 5,400 9,138 4,145 4,499 2,041 Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º) Lbs.** kg** 22,613 10,257 15,306 6,943 11,749 5,329 5,784 2,624 Description Quantity Winch assembly with wire rope including lead wires 1 Circuit breaker assembly with hardware 1 Handsaver 1 Mounting hardware kit 1 Remote pendant 1 Owner’s manual 1 This carton contains the following items. Please unpack carefully. Read instructions before beginning. U N PA C K I N G D I M E N S I O N S S3000, S4000, S5000 Figure 2 P E R F O R M A N C E Wire Rope Max. Pulling Capacity Layer lbs. kg 1 3,000 1364 2 2,250 1021 3 2,000 907 4 1,750 794 Motor Load Speed Current lbs. kg ft/min m/min Amps 0 0 17.0 5.1 15 1,000 454 12.5 3.8 70 2,000 907 9.0 2.7 117 2,500 1134 7.5 2.3 155 3,000 1361 4.5 1.4 220 S3000 Wire Rope Max. Pulling Capacity Layer lbs. kg 1 4,000 1818 2 3,000 1361 3 2,600 1179 4 2,000 998 Motor Load Speed Current lbs. kg ft/min m/min Amps 0 0 21.6 6.5 30 1,000 454 16.0 4.8 90 2,000 907 12.4 3.8 155 2,500 1134 10.6 3.2 180 3,000 1361 8.8 2.7 215 3,500 1589 6.2 1.9 250 4,000 1814 4.5 1.4 311 Wire Rope Max. Pulling Capacity Layer lbs. kg 1 5,000 2273 2 4,000 1814 3 3,500 1588 4 2,900 1315 Motor Load Speed Current lbs. kg ft/min m/min Amps 0 0 17.5 5.9 36 1,000 454 14.5 4.6 80 2,000 907 12.0 3.4 135 3,000 1361 9.5 2.2 200 4,000 1814 7.3 1.3 265 5,000 2268 4.5 1.4 350 S4000 S5000 * Based on first layer performance NOTES 1. All dimensions are in inches [millimeters]. 2. Typical mount is to flat surface capable of handling the loads. Bolts to be Grade 5 or better. 6.0 (152) 15.1 (383) 7.2 (183) 7.1 (180) 3.1 (79) 5.9 (150) 3.69 (93.7) 1.24 (31.5) ROLLER FAIRLEAD SCREWS DRUM SUPPORT PLATE SCREWS MOTOR SCREWS 4 5 DRUM SUPPORT PLATE Your S series winch is a very powerful machine. Treat it with respect, use it with caution and always follow the safety guidelines. The wire rope may break before the winch stalls. For heavy loads, use a pulley block to reduce the load on the wire rope. 1. The S3000, S4000, and S5000 winch is rated at 3,000, 4,000, and 5,000 pounds (1361, 1814, 2268 kg) (single line) capacity on the wire rope layer closest to the drum. DO NOT OVERLOAD. DO NOT ATTEMPT PROLONGED PULLS AT HEAVY LOADS. Do not maintain power to the winch if the motor stalls. Overloads can damage the winch and/or the wire rope and create unsafe operating conditions. FOR LOADS OVER 2/3 RATED CAPACITY, WE RECOMMEND THE USE OF THE OPTIONAL PULLEY BLOCK TO DOUBLE LINE THE WIRE ROPE (Figures 3 & 18). This reduces the load on the winch and the strain on the wire rope by approximately 50%. If attaching back to vehicle, attach to the frame or other load bearing part. The vehicle engine should be running during winch operation to minimize battery drain and maximize winch power and speed. If considerable winching is performed with the engine off, the battery may be too weak to restart the engine. 2. AFTER READING AND UNDER- STANDING THIS MANUAL, LEARN TO USE YOUR WINCH. After installing the winch, practice using it so you will be familiar with it when the need arises. 3. DO NOT “move” your vehicle to assist the winch in pulling the load. The combination of the winch and vehicle pulling together could overload the wire rope and the winch. 4. KEEP WINCHING AREA CLEAR. Do not allow people to remain in the area during winching operations. ALWAYS STAND CLEAR OF WIRE ROPE, HOOK AND WINCH. IN THE UNLIKELY EVENT OF ANY COM- PONENT FAILURE, IT IS BEST TO BE OUT OF HARM‘S WAY. 5. INSPECT WIRE ROPE AND EQUIP- MENT FREQUENTLY. A FRAYED WIRE ROPE WITH BROKEN STRANDS SHOULD BE REPLACED IMMEDIATELY. Always replace wire rope with the manufacturer‘s identical replacement part (see Replacement Parts List). Periodically check the winch installation to ensure that all bolts are tight. 6. USE HEAVY LEATHER GLOVES when handling wire rope. DO NOT LET WIRE ROPE SLIDE THROUGH YOUR HANDS EVEN WHEN WEARING GLOVES. 7 G E N E R A L S A F E T Y I N F O R M AT I O N Figure 3 Single Line Double Line I N T E R M I T T E N T D U T Y An electric winch is like any other motor driven power tool such as an electric drill or saw. The electric motor should not be allowed to become excessively hot. Normal precautions will extend the life of your motor. Keep the duration of pulls as short as possible. If the end of the motor becomes uncomfortably hot to touch, stop winching and allow the motor to cool down. If the winch motor stalls, do not continue to apply power to the winch. 6 F E AT U R E S Electric Motor – 1.3 (S3000), 1.8 (S4000), 2.1 (S5000) peak hp (.97 (S3000), 1.34 (S4000), 1.57 (S5000) kW) 12V or 24Volt Permanent Magnet. Braking – A wrap spring brake which will hold 50% of rated load on the first wrap. Reducing by approximately 10% per layer thereafter. Drum – Die cast aluminum running in maintenance free bearings. Freespool Clutch – Operated by an easy action lever which disen- gages the gearbox to allow the wire rope to be pulled out without using electric power. A tension plate reduces backlash and snarling when pulling out the wire rope. Remote Switch – 30' (13.64 m) hand held pendant switch assembly with toggle switch. Mounting – Optional custom engineered mounting kits are available for vehicle frame attachment. European Union Noise The noise level of this winch in operation is below 92 dB(A). Emergency Stop In order to conform to Machinery Directive 89/392/EEC, each machine installation must be fitted with an Isolator (Part Number 8370) whereby the machine can be brought safely to a complete stop.