REVO 10S | REVO 10W | REVO 12S | REVO 12W
Congratulations on the purchase of your Bushranger vehicle recovery winch. This product has been designed to meet the specified applications (see limitations below in ‘Warning’) and with proper care and preventative maintenance will give you years of trouble-free operation. All information in this publication is based on the latest production information available at the time of print. We reserve the right to make changes without notice because of continued product improvement.
Warnings Table of contents 1. It is highly recommended that prior to using this off road vehicle recovery winch, that users undertake off road training including vehicle recovery. Recovering immobilised vehicles is a potentially dangerous exercise and this winch is to be used with great care. 2. The winch is rated at the first layer of rope on the drum for intermittent periodic duty. Introduction 1 3. 4.
•• •• •• •• •• •• •• •• •• •• •• •• •• •• When winching, always use a recovery damper. Place over the rope in the middle third of its length. A rope should be replaced if it shows signs of excessive wear, broken strands, corrosion for wire rope and excessive abrasion or fused and melted fibre for synthetic rope or any other defects. If the winch fails to pull a load under normal conditions, manually stop the operation, otherwise motor damage may occur.
Control box mounting Mounting Option 2 - Directly to winch The Control Box has been designed with multiple mounting options to suit a variety of mounting locations and orientations. The “Bushranger” stick on label is supplied loose in your winch kit and should be adhered to the Control Box once a suitable mounting method has been chosen and the correct orientation is known. The Control Box may be fitted to the cross bars of the winch.
Gearbox Rotation Motor Rotation The gearbox end of the winch can be rotated in 22.5° increments to allow for the clutch handle to be orientated to best suit the installation requirements. The motor can be rotated to 3 positions in 90° increments to allow for repositioning of the poles to best suit the installation requirements. These positions are @ 0°, 90° and 270°. 1). Loosen and partially remove the 8 x bolts (see important note and red arrows below) that secure the two gearbox sections to the winch.
Wiring Diagram Nut Fastening for Motor & Contactor Attach the black lead firmly to the negative (–) battery terminal and red lead to the positive (+) battery terminal. The voltage drop for the winch motor must not exceed 10% of the nominal voltage of 12V. For best performance, mount the winch as close to the battery as possible. The nuts on the motor and contactor should be fastened to the s pecified torqueas outlined in the diagram below.
Winching Principles Required Pulling Force NOTE: Kingsley Enterprises Pty. Ltd. recommend that prior to using this recovery equipment, users should undertake formal training from an accredited industry body in winch use and vehicle recovery. Calculating Fleet Angle To obtain the best rope service, the direction of pull should be on a horizontal plane within ±15 degrees and perpendicular to the centreline of the winch drum within ±15 degrees.
Accessories Winching Procedures Snatch Block Important Notes Before Operating the Winch A snatch block is an important aid to successful winching and can be used to increase the pulling power (or mechanical advantage) of a winch, or change the direction of a pull. Where a double line pull is used (i.e. where a snatch block is used at the load or anchor point and the winch rope is connected back to the vehicle), twice the pull force is applied but the speed of recovery is halved.
Clearing the Receiver Memory Cable-in/Cable-out Operation 1. Ensure that the wireless receiver is turned OFF. 2. Turn on the new wireless hand controller in wireless mode by pressing and holding the POWER button ( ) for 3 seconds. 3. Press and hold the “IN” and “OUT” buttons on the new hand controller at the same time.
Preparation before Winching Anchor Point When choosing an anchor point, select a firm point such as a tree, stump or rocks. DO NOT WRAP THE ROPE AROUND THE ANCHOR POINT AND BACK ONTO ITSELF. Always use a tree trunk protector strap to prevent ring barking the tree and damage to the rope. If using a winch to retrieve another stranded vehicle, the rescue vehicle is considered the anchor point and should be made secure.
Precautions whilst winching 5) Begin winching 6) Secure vehicle Keep tension on the rope to ensure it winds onto the drum tightly and evenly and does not sink into the lower layers. Release Hand brake and continue pulling until the vehicle is recovered. Once the vehicle is secured, wind the remaining rope back onto the drum tightly and evenly and secure the hook firmly. ISOMETRIC VIEW N.T.S. FLAT PATTERN SCALE Make sure the rope is wound onto the drum tightly and evenly.
Maintenance 7. Wire Rope Replacement Always use a replacement rope that is correctly rated for the capacity of the winch. Use the following method to replace the wire rope: 1. 2. 3. 4. 5. 6. 7. 8. Disengage the clutch handle. Spool out the entire wire rope, loosen the set screw and then remove the rope from the drum. Feed the replacement wire rope through the roller fairlead opening, pass below the drum, and insert it into the hole on the drum end. Tighten the set screw to secure the wire rope.
Lubrication & Servicing Servicing and repairs should only be carried out by an authorised dealer. Unauthorised repairs or servicing will void warranty. The maintenance scheduled should be followed to ensure reliable operation for the life of the winch. The winch should be used regularly to ensure components are kept in good working order. At a minimum, it is recommended that the rope is powered out and then powered back in on a monthly basis by following the correct winching procedures (Page 14).
REVO 10 Specifications Performance Specifications: Specifications: 1st Layer of Drum Line Pull Motor 12V Gear Train Gear Ratio Free-spool Brake Rope Size Drum Size Mounting Bolts Pattern IP Rating Winch weight (no rope) Fitted weight Gross weight Load (kg/lb) No load 1816/4000 2724/6000 3632/8000 4540/10000 4536kg/10,000lb 3.9kW/5.2hp 4 stage planetary 171:1 Rotating ring gear Gearbox Mounted, Proportional Friction Braking System Synthetic - 10mm x 28m (25/64” x 92’), Wire - 9.
REVO 10 Synthetic Model Parts List & Winch Assembly Winch Assembly – REVO 10 Synthetic Item No: Description Qty Item No: Description Qty Item No: Description Qty Item No: Description Qty 1 Gearbox End Socket Head Cap Screw M5*75 8 25 3rd Stage Rotating Ring Gear 1 49 Synthetic Rope 10mm x 28mm 1 73 Motor End Cover 1 2 Spring Washer Ø5 26 26 Clutch Pin 1 50 Motor Output Shaft 1 74 Control Box Mounting Bracket 1 3 Gearbox End Cover 1 27 Clutch Pin O Ring Small 1 51
Winch Assembly – REVO 10 Synthetic REVO 10 Wire Model Parts List & Winch Assembly Item No: Page 29 | REVO VEHICLE RECOVERY WINCH Description Qty Item No: Description 1 Gearbox End Socket Head Cap Screw M5*75 8 25 3rd Stage Rotating Ring Gear 1 2 Spring Washer Ø5 26 26 Clutch Pin 1 3 Gearbox End Cover 1 27 Clutch Pin O Ring Small 1 4 O Ring Seal 3 28 Clutch Pin O Ring Large 1 5 Gearbox Cover Ratchet Bearing 1 29 Clutch Cam 1 6 First Stage Gear Shaft 1 30 Clutch Spring
Winch Assembly – REVO 10 Wire Item No: Description 49 Wire Rope 1 66 Control Box Electrical Socket 1 50 Motor Output Shaft 1 67 Drum Assembly 1 51 Tie Bar Socket Head Cap Screw M8*25 4 68 Drum Support Motor Side 1 52 Tie Bar Spring Washer Ø8 4 69 Motor Coupling 1 53 Tie bar 2 70 10K Motor Cover 1 54 Contactor Mounting Flange Nut M5 2 71 Motor Cover Socket Head Cap Screw M5x50mm 6 55 Roller Fairlead 1 72 10K Motor Assembly 1 56 Control Box Backing Plate 1 73 Mo
REVO 12 Specifications Performance Specifications: Specifications: 1st Layer of Drum Line Pull Motor 12V Gear Train Gear Ratio Free-spool Brake Rope Size Drum Size Mounting Bolts Pattern IP Rating Winch weight (no rope) Fitted weight Boxed weight Load (kg/lb) No load 1816/4000 2724/6000 3632/8000 4540/10000 5443/12000 5443kg/12,000lb 4.6kW/6.2hp 4 stage planetary 171:1 Rotating ring gear Gearbox Mounted, Proportional Friction Braking System Synthetic - 11mm x 24m (7/16” x 78’), Wire - 10.
REVO 12 Synthetic Model Parts List & Winch Assembly Winch Assembly – REVO 12 Synthetic Item No: Description Qty Item No: Description Qty Item No: Description Qty Item No: Description Qty 1 Gearbox End Socket Head Cap Screw M5*75 8 25 3rd Stage Rotating Ring Gear 1 49 Synthetic Rope 11mm x 24m 1 73 Motor End Cover 1 2 Spring Washer Ø5 26 26 Clutch Pin 1 50 Motor Output Shaft 1 74 Control Box Mounting Bracket 1 3 Gearbox End Cover 1 27 Clutch Pin O Ring Small 1 51
Winch Assembly – REVO 12 Synthetic REVO 12 Wire Model Parts List & Winch Assembly Item No: Description Qty Item No: Description 1 Gearbox End Socket Head Cap Screw M5*75 8 25 3rd Stage Rotating Ring Gear 1 2 Spring Washer Ø5 26 26 Clutch Pin 1 3 Gearbox End Cover 1 27 Clutch Pin O Ring Small 1 4 O Ring Seal 3 28 Clutch Pin O Ring Large 1 5 Gearbox Cover Ratchet Bearing 1 29 Clutch Cam 1 6 First Stage Gear Shaft 1 30 Clutch Spring 1 7 First Stage Anti-Wear Washer 1
Winch Assembly – REVO 12 Wire Item No: Description 49 Wire Rope 1 66 Control Box Electrical Socket 1 50 Motor Output Shaft 1 67 Drum Assembly 1 51 Tie Bar Socket Head Cap Screw M8*25 4 68 Drum Support Motor Side 1 52 Tie Bar Spring Washer Ø8 4 69 Motor Coupling 1 53 Tie bar 2 70 12K Motor Cover 1 54 Contactor Mounting Flange Nut M5 2 71 Motor Cover Socket Head Cap Screw M5x50mm 6 55 Roller Fairlead 1 72 12K Motor Assembly 1 56 Control Box Backing Plate 1 73 Mo
KINGSLEY PRODUCTS - WARRANTY POLICY 1. Our Warranty We warrant to you that the Kingsley product is free from defects in workmanship and materials for the warranty period. 2. Fitting and use Please ensure you: a. fit the Kingsley product in accordance with the product information and all relevant vehicle safety and compliance laws b.
