Product Manual

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). The drum support seals are a wearing item and are critical to retaining
the sealed design of the winch. These should be inspected and greased or replaced as required depending on
the frequency of use and the operational environment.
All moving parts in the winch are permanently lubricated at the time of assembly. Under normal conditions,
factory lubrication will sufce. If re-lubrication of the gear box is necessary after repair or disassembly, use Shell
EP2 or equivalent grease. The clutch handle can be lubricated regularly with light oil.
Only use low pressure water to clean the synthetic rope. Do not use any chemicals. We recommend using low
pressure water and a soapy sponge to clean the winch. If high pressure water is used, do not direct it at the
drum area or the clutch handle. Using high pressure water in these areas can force water past seals and lead
to internal water build up which can damage the winch.
Lubrication & Servicing
Cleaning
Maintenance Schedule
1. Ensure that a responsible person carries out all inspections as per schedule.
2. Inspections are divided into Daily, Monthly and Three Months.
Classication of check
Item
Checking
Method Checking Reference
Daily
Periodical
One
month
Three
months
O Installation
Mounting bolts &
alignment
Bolt tension &
wear
Existence of abnormalities
O
Remote
control
Correct operation Manual Reasonable actuation
O
Wire rope
Broken strands Visual, measuring Less than 10%
O O
Decrease in rope
diameter
Visual, measuring
7% of nominal diameter
max
O Deforming or corrosion Visual Existence of abnormalities
O
Fastening to hook and
drum assemblies
Visual Existence of abnormalities
O
Synthetic
rope
Broken strands
Visual, measuring Two or more adjacent
strands are cut
O O
Decrease in rope
diameter
Visual, measuring 25% of nominal diameter
max
O Fused or melted bres Visual Existence of abnormalities
O
Fastening condition
of end
Visual
Existence of abnormalities
O
Clutch
assembly
Damaged clutch
assembly
Visual evidence
of wear
Free of wear or damage
O Motor Staining, damage
Visual evidence
of wear
Existence of abnormalities
O
Brake
Ability to hold loads Visual Reasonable actuation
O
Gears
Smooth operation Visual, auditory Reasonable actuation
O Seals
Damaged or
worn seals
Visual evidence
of wear
Free of wear or damage
Troubleshooting
If the winch fails to operate after several attempts, or if there is any fault
whilst operating:
Wire Rope Replacement
Symptom Possible Cause Remedy
Winch will not
operate
Cut circuit Check battery lead
Weak battery
Recharge or replace battery
(at least 650CCA)
Bad connection of wirings Reconnect tightly
Damaged contactor Replace contactor
Cut circuit on switch Replace switch
Damaged motor or worn brushes Replace motor or brushes
Faulty motor wirings Replace wirings
Motor runs
in only one
direction
Broken wirings or bad connections Reconnect or replace wirings
Damaged or stuck contactor Replace contactor
Switch inoperative Replace switch
Faulty wiring Replace wiring
Drum will not
free spool
Clutch does not disengage Engage clutch
Damaged 1st stage shaft Replace 1st stage shaft
Damaged brake Replace brake
Damaged motor output shaft Replace motor output shaft
Brake fails to
operate
The gear train is mechanically
binding up
Check to insure the winch is mounted on
a at, rigid surface
Damaged brake Replace brake
Damaged gear box Replace gear box
Damaged ratchet Replace ratchet components
Braking
distance is too
long
Worn brake Replace brake
Brake jam
Proportional mechanism is
damaged or worn
Replace
Damaged
gear box
Hit by certain exterior force Replace the damaged components
Damaged gear train Replace the damaged components
Over load operation
Stop the winch operation and
reduce a load
Motor runs
extremely hot
Long period of operation Allow to cool
Damaged motor Replace or repair motor
Damaged or inoperative brake Replace or repair brake
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