Specifications

ManualsBrandsConnectGear ManualsComputer equipmentGR-D04T1+

Installation Instructions

X2O Winches

SAFETY PRECAUTIONS

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

Warning! Observe safety precautions for personal safety and the safety of others. Improper

equipment operation may cause personal injury and equipment damage.

Read the following carefully before attempting to operate your winch and keep the instructions

for future reference.

1. Dress properly:

-Don’t wear loose clothing or jewelry. They can be caught in moving parts.

-Wear leather gloves when handling winch cable. Do not handle cable with bare hands as

broken wires can cause injuries.

-Non-skid footwear is recommended

2. Keep a safe distance:

-Ensure that all persons stand well clear of winch cable and load during winch operation, 1.5

times the cable length recommended. If a cable pulls loose or breaks under load, it can lash

back and cause serious personal injury or death.

-Don’t step over the cable.

-All visitors and onlookers should be kept away from the work area.

-Keep proper footing and balance at all times.

3. Don’t’ abuse the cord:

-Never carry your winch by the cord or yank it to disconnect it from the receptacle.

-Keep cord from heat, oil and sharp edges.

4. Don’t overwork the winch:

-If the motor becomes uncomfortably hot to touch, stop and let it cool for a few minutes.

-Don’t maintain power to the winch if the motor stalls.

-Don’t exceed maximum line pull ratings shown in tables. Shock loads must not exceed these

ratings.

5. Avoid unintentional starting:

-Winch clutch should be disengaged when not in use and fully engaged when in use.

6. Check damaged parts:

-Before using, you should check your winch carefully. Any part that is damaged should be

properly repaired or replaced by an authorized service centre.

7. Repair your winch:

-When repairing, use only identical replacement parts or it may cause considerable danger for

the user.

8. Re-spool the cable:

-Leather gloves must be worn while re-spooling. To re-spool correctly, it is necessary t keep a

slight load on the cable. Hold the cable with one hand and the remote control switch with the

NOTE: Read entire manual thoroughly before installing and using this

product.

Keep manual with winch for

reference, warranty and

future use.

Summary of content (22 pages)

PAGE 1
Installation Instructions X2O Winches NOTE: Read entire manual thoroughly before installing and using this product. Keep manual with winch for reference, warranty and future use. SAFETY PRECAUTIONS Warning! Observe safety precautions for personal safety and the safety of others. Improper equipment operation may cause personal injury and equipment damage. Read the following carefully before attempting to operate your winch and keep the instructions for future reference. 1.
PAGE 2
Installation Instructions X2O Winches other. Start as far back and in the centre as you can. Walk up keeping load on the cable as the winch is powered in. -Do not allow the cable to slop through your hand and do not approach the winch too closely. -Turn off the winch and repeat the procedure until all the cable except 1m is in. -Disconnect the remote control switch and finish spooling in cable by rotating the drum by hand with clutch disengaged.
PAGE 3
Installation Instructions X2O Winches 11. Since the greatest pulling power is achieved on the innermost layer of your winch, it is desirable to pull off as much line as you can for heavy pulls(you must leave at least 5 wraps minimum on the drum----red cable). If this is not practical use a snatch block and double line arrangement. 12. Draping a heavy blanket or similar object over the extended winch cable is recommended as it will dampen any back lash should a failure occur. 13.
PAGE 4
Installation Instructions X2O Winches 20. The winches shown in this manual are solely for vehicle and boat mounted, nonindustrial applications. 21. Do not use winch in hoisting applications due to required hoist safety factors and features. 22. Do not use the winch to lift, support or otherwise transport personnel. INSTALLATION Mounting your winch 1. The winch is to be mounted into a suitable steel mounting frame using the 4 point foot mounting system in either a horizontal or vertical plane.
PAGE 5
Installation Instructions X2O Winches X20- 8,000 X20-10,000, 12,000 X20- 15,000
PAGE 6
Installation Instructions X2O Winches Lubrication installation All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly. Lubricate cable periodically using light penetrating oil. Inspect for broken strands and replace if necessary. If the cable becomes worn or damaged it must be replaced. Cable installation Unwind the new cable by rolling it along the ground, to prevent kinking.
PAGE 7
Installation Instructions X2O Winches To Battery + To Battery (Diagram 1) Note: 1. Your battery must be kept in good condition. 2. Be sure battery cables are not drawn taught across any surfaces, which could possibly damage them. 3. Corrosion on electrical connections will reduce performance or may cause a short. 4. Clean all connections especially in remote control switch and receptacle. 5. In salty environments use a silicone sealer to protect from corrosion. 6.
PAGE 8
Installation Instructions X2O Winches Installing the control box It is recommended to install you winch control box prior to installing your winch.
PAGE 9
Installation Instructions X2O Winches Step 2: Install the control box by lining it up with the two holes on the motor side upright, then Secure with the included hardware. (Fig E, F) (Fig D) (Fig E) (Fig F) Remote Control Do not force end of remote plug into the plug on the control box. Line the tab on the inside of the remote socket end with the groove on the remote plug on the control box. (Fig G,H) Push the toggle switch upward to operate the winch “Outward” .
PAGE 10
Installation Instructions X2O Winches Winch Operation The best way to get acquainted with how your winch operates is to make a few test runs before you actually need to use it. Plan your test in advance. Remember you can hear your winch as well as you can see it operate. Get to recognize the sound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Soon you will gain confidence in operating your winch and its use will become second nature to you. Operating 1.
PAGE 11
Installation Instructions X2O Winches 1. Never winch with your vehicle in gear or in part, which would damage your vehicle’s transmission. 2. Never wrap the cable around the object and hook onto the cable itself. This can cause damage to the object being pulled, and kink or fray the cable 3. Keep hands, clothing, hair and jewellery clear of the drum area and cable when winching. 4. Never use the winch if the cable is frayed, kinked or damaged. 5.
PAGE 12
Installation Instructions X2O Winches Understanding IP Ratings The first digit indicates the level of protection that the enclosure provides against access to hazardous parts (e.g., electrical conductors, moving parts) and the ingress of solid foreign objects. The second digit indicates protection of the equipment inside the enclosure against harmful ingress of water.
PAGE 13
Installation Instructions X2O Winches Level 0 Protected against Not protected Testing for — Details — Test duration: 10 minutes 1 Dripping water Dripping water (vertically falling drops) shall have no harmful effect. Water equivalent to 1mm rainfall per minute Test duration: 10 minutes 2 Dripping water when tilted up to 15° Vertically dripping water shall have no harmful effect when the enclosure is tilted at an angle up to 15° from its normal position.
PAGE 14
Installation Instructions X2O Winches Gear Housing “Clocking” In some situations you may need to “Clock” (turn) your Gear Housing in order to gain access to them. To clock the Gear Box Step 1: Loosen and remove the two tie Step 1: the tie rod bolts onLoose the gear box side.
PAGE 15
Installation Instructions X2O Winches 8000lbs Features and Specifications Single line rated pull Motor Control Gear train Gear reduction ratio Clutch Braking Drum size Cable Fairlead Remote Control Battery Battery Leads Net weight Overall dimension (length x width x height) Mounting bolt pattern 8000lbs (3600kgs) 5.5 hp series wound 12’ Remote Switch 3 stage planetary 150:1 Sliding Ring Gear Automatic In-The-Drum Diameter 2.5”(63.5mm) x length 8.8”(224mm) 5/16”(8.1mm) x 98.
PAGE 16
Installation Instructions X2O Winches 10,000lbs Features and Specifications Single line rated pull Motor Control Gear train Gear reduction ratio Clutch Braking Drum size Cable Fairlead Remote Control Battery Battery Leads Net weight Overall dimension (length x width x height) Mounting bolt pattern Line pull lbs(kgs) 0 2000 (907) 4000 (1814) 8000 (3628) 10000 (4536) Layer 1 2 3 4 10000lbs (4318kgs) 5.
PAGE 17
Installation Instructions X2O Winches 12000lbs Features and Specifications Single line rated pull Motor Control Gear train Gear reduction ratio Clutch Braking Drum size Cable Remote control switch Battery Battery Leads Net weight Overall dimension (length x width x height) Mounting bolt pattern Line pull lbs(kgs) 0 3000 (1361) 6000 (2727) 9000 (4082) 12000 (5454) Layer 1 2 3 4 12000lbs (5454kgs) 6.
PAGE 18
Installation Instructions X2O Winches 15000lbs Features and Specifications Single line rated pull Motor Control Gear train Gear reduction ratio Clutch Braking Drum size Cable Remote control switch Battery Battery Leads Net weight Overall dimension (length x width x height) Mounting bolt pattern Line pull lbs(kgs) 0 4000 (1701) 75000 (3402) 11250 (5103) 15000(6818) Layer 1 2 3 4 15000lbs (6818kgs) 6.6hp Series Wound 12’ Remote switch 3 stage planetary 420:1 Sliding Ring Gear Automatic In-The-Drum 3.
PAGE 19
Installation Instructions X2O Winches X20 Winch Components Diagram
PAGE 20
Installation Instructions X2O Winches X20 Winch Components List 8000 lbs 10000lbs 12000lbs Description Part No on drawing 97380-01 97310-01 97312-01 Sun Gear-Input 1 97380-02 97310-02 97312-02 Gear Carrier-Input 2 97380-03 97380-03 97380-03 Gear Carrier-Intermediate 3 97380-04 97380-04 97380-04 Washer-1.
PAGE 21
Installation Instructions X2O Winches 8000 lbs 10000lbs 12000lbs Description Part No on drawing 97380-32 97380-32 97312-32 Gear Box End Cover 32 97380-33 97380-33 97380-33 Bolt + Spring Washer 33 97380-36 97380-36 97380-36 Bearing 36 97380-38 97380-38 97380-38 Locking Pin 38 97380-39 97380-39 97380-39 Clutch Lever 39 97380-41 97310-41 97312-41 Wire Rope 41 97380-42 97380-42 97380-42 Wire Rope Fix Bolt 42 97380-43 97380-43 97380-43 Screw 43 97380-44 97380-44 97
PAGE 22
Installation Instructions X2O Winches Compliment your new Winch with a Smittybilt Winch Cover or other Smittybilt products SMITTYBILT WINCH Winch Access.