Page 1
Vr. 1
Installation & Operation Manual
Electric
Winch
Page 2
Technical Information
Features
• 2.7Kw (3.6Hp) permanent magnet motor
• Dustproof contactor controls for longer life
and improved amperage draw
• Planetary gear system for fast line speed
• Free spooling
• Low electric current
• Automatic load-holding brake
• Power in and power out
Specifications
•Rated Line Pull - single line 2,724kgs 6,000lbs
• Gear Reduction Ratio 210:1 210:1
• Motor - permanent magnet - 12 volts 2.7Kw 3.6Hp
• Drum Size (D x L) 63 x 140mm 2.5 x 5.51”
• Cable supplied - maximum break force 10,000lbs 7.94mm x 26m 0.31” x 85’
Galvanised aircraft cable
• Overall Dimension (L x W x H) 438 x 158 x 185mm 17.24 x 6.22 x 7.28”
• Net Weight 31.8kgs 70lbs
• Mounting Bolt Pattern 166 x 114.3mm 6.535 x 4.5”
2
Line Pull & Cable Capacity by Layer
Rated Line Pull Cable Capacity
Cable Layer Lbs Kgs Feet Meters
1 6,000 2,722 12.7 3.87
2 5,000 2,268 27.5 8.38
3 4,250 1,928 44.0 13.41
4 3,720 1,687 64.0 19.51
5 3,300 1,497 85.0 25.91
Line Pull Line Speed Motor Current
Lbs Kgs Fpm Mpm Amp
0 0 15.0 4.6 30
1,000 454 11.5 3.5 80
3,000 1,361 9.0 2.7 120
5,000 2,268 7.0 2.0 170
6,000 2,722 4.9 1.5 210
Performance of 1st Layer
Page 3
Safety Warnings & Precautions
3
•Learn How To Use Your Winch
After the winch has been installed, take some time to practice
using the winch so that you are familiar with its operation.
Periodically check the winch installation to ensure all nuts and
bolts are tight. To ensure proper operation, carefully inspect
for any damaged parts before operating the winch. Any
damaged part should be repaired or replaced.
•Keep Winching Area Clear
Do not allow people to remain in the area during winching
operations. Do not step over a taut wire rope or allow anyone
else to do so. A snapped wire rope could cause injury or death.
Keep proper footing and balance at all times. Do not reach
over or across the winch and/or wire rope or come between
the winch and load whilst the winch is in operation.
•Inspect Winch Rope & Equipment Frequently
The winch rope should be inspected for damage that can
reduce its breaking strength. A frayed rope with broken
strands should be replaced immediately. Never use a wire
rope that shows signs of weakening is knotted or kinked.
Plasma rope can be cleaned by unspooling into a bucket of
clean water and tumble rope in the water until clean - check
the condition. Always replace the rope with one of the correct
rating for the winch. Examine the winch before using as
components may be affected by exposure to everyday
weathering, chemicals, salts and rusts etc.
•Working Area Conditions
Keep the working area well lit. Do not use the winch in the
presence of flammable gasses or liquids.
•Keep Children Away
Keep children away from the working area and never let
children operate the winch.
Hazard! Stay clear of winch rope
when winch is in operation!
Place tree protect sling low
on the tree!
Never connect the winch rope
to itself!
Keep hand and fingers clear of
winch rope and hook when
operating the winch!
Never try to use yourself or anyone
else as a secure place to hook a
winch too!
Frequently inspect the winch rope
and all other winch equipment!
Never consume alcohol when
operating the winch!
Always wear protection on
your hands!
Always leave at least 5 turns of
cable on the drum!
When operating this winch, safety precautions should always be followed to reduce
the risk of personal injury and damage to the winch.
Page 4
Safety Warnings & Precautions
4
•Wear Gloves
W
hen handling or rewinding the wire rope, always use
hand protection to eliminate the possibility of cuts
c
aused by burrs and slivers from broken strands.
•
Secure Vehicle
Be sure to secure vehicle in position before using the
winch and after moving an item with the winch secure
the item. Do not rely on the winch to hold it for an
e
xtended period as the winch does not have a locking
mechanism. Apply blocks (such as a wheel choke) to
vehicle when parked on an incline.
•Drum Rope
Do not apply load to winch when the wire rope is fully
extended. Always make sure that there are at least 5
complete turns of rope left on the drum before starting
to winch. Take care to ensure the wire rope is respooled correctly.
•Keep Hands & Fingers Clear Of Wire Rope &
Hook When Operating Winch
Never put your finger through the hook when reeling in
the last few feet. If your finger gets trapped in the hook
or rope you could loose it. Never guide the wire rope
under tension onto the drum with your hand. Always
keep hands and body away from the fairlead (cable
intake slot) when operating the winch.
•Never Hook The Wire Rope Back Onto Itself
Hooking the rope back onto itself creates an
unacceptable strain, breaking individual strands, which
in turn weakens the entire wire rope.
•Keep Pulling Durations As Short As Possible
The winch is designed for intermittent use and cannot
be used in constant duty applications. Do not pull for
more than one minute at or near the rated load. If the
motor becomes too hot to touch, stop and let it cool off
for a few minutes. If the motor stalls then cut off the
power immediately.
•Do Not Overload
Always use the winch below its rated capacity for your
safety and better performance of the winch. Do not use
inappropriate attachments in an attempt to exceed its
rated capacity.
•Avoid Continuous Pulls From Extreme Angles
This will cause the rope to pile up at one end of the
drum. When feasible, get the rope as straight as
possible to the direction of the object.
•Never Operate The Winch Without The Rope
Fairlead Fitted
Operator injury or winch damage can result if a fairlead
is not installed.
•Stay Alert
W
atch what you are doing at all times. Use your
common sense. Do not use this winch when you are
t
ired, stressed or when under the influence of drugs,
alcohol or medication.
•Disconnect Switch
Rotate switch to stop in an emergency.
•Stay Alert
When servicing, use only identical replacement parts.
Use of any other parts will void the warranty.
•Check Winch Is Secure
Be certain that winch is properly bolted to a structure
or vehicle that can hold the winch load.
•Use The Right Couplings
Always use the proper couplings when connecting the
winch cable to the load.
•Use Horizontally
Never lift items vertically as the winch was designed for
horizontal use only. Never lift people or hoist loads over
people.
•Inappropriate Attachments
Do not use any inappropriate attachments to extend
the length of the winch cable.
•...And Finally
The warnings, cautions and instructions in this manual
cannot cover all the possible conditions and situations
that may occur. It must be understood, by the operator,
that common sense and cautions are factors that
cannot be built into this product but must be exercised
by the operator.
EC Declaration of Conformity
Border Holdings (UK) Ltd
Britpart, The Grove,
Craven Arms, Shropshire,
SY7 8DA, UK
Part Numbers DB12000i, DB9500i, DB9000C, DB8000,
DB6000 & DB2000
Description Electric Winches
We hereby declare that above mentioned winches are compliant
with the essential requirement of Directive 2006/42/EC,
2006/95/EC and satisfy the standards of ISO 12100-2010, BS
EN60204-32:2008 in their application of pulling a load.
Page 5
Installation
5
Installation
If the winch has a plasma rope fitted this will have to
b
e removed prior to fitment as the hook is not
removable and the rope will have to be threaded
t
hough the fairlead once the winch is fixed in place.
Refer to operation section on how to replace cable for
removal.
Step One
Mount electric winch to the vehicle using nuts and bolts
provided. If the provided hardware does not
accommodate the installation, use SAE grade 8.8 bolts
or higher with torque to 35ft/lbs. It should be aligned
and secured to a solid part of the vehicle (front or rear)
where the full rated load will be evenly distributed. Also
remember that the winch is designed for horizontal not
vertical pull.
Step Two
Connect the red (positive) battery cable from the
solenoid assembly to the closest screw-down positive
(+) terminal to 12 volt battery.
Caution - Battery cables should not be drawn taut.
Leave slack for some cable movement.
Step Three
Connect the black (negative) battery cable from solenoid
assembly to the closest screw-down negative (-)
terminal to 12 volt battery.
Step Four
Test electric winch for proper operation. Refer to the
operation section.
Page 6
Operation
6
Operation
Step One
Lift the female connector cover exposing the electrical
s
witch connector.
S
tep Two
Insert the switch assembly connector onto the female
connector
S
tep Three
Disengage the clutch by moving cam ring or rotating
lever to the OUT position.
Step Four
Grab the cable assembly hook and pull the cable to the
desired length then attach to item being pulled.
Caution - Always leave at least 5 turns of cable on
the drum. Read over winch safety warning and
precautions before continuing.
Step Five
Re-engage the clutch by moving the cam ring or rotating
lever to the IN position.
Step Six
While standing aside the vehicle, move the rocker
switch backwards and forwards to change direction of
the winch, wait for the motor to stop before reversing
direction.
Step Seven
When the towing is complete, remove the switch
assembly from the female connector and replace the
female connector cover.
Cautions
Run the vehicle engine during towing operations to keep
the battery charging.
When towing a heavy load, place a blanket or similar
over the cable 5 - 6 feet (1.5m - 1.8m) from the hook.
In an emergency switch off the kill switch immediately
to cut off the electricity and stop the winch.
Lubrication
No internal lubrication is required as all moving parts
inside the winch have been lubricated using high
t
emperature lithium grease at the factory. Lubricate
cable every so often using a light penetrating oil.
Rope Assembly Replacement
Step One
Move cam ring to out position
Step Two
Extend cable assembly to its full length. Note how the
existing cable is connected to the inside of the drum
Step Three
Remove old cable assembly and attach new one.
Step Four
Retract cable assembly onto cable drum being careful
not to allow kinking. The winch rope must be rewound
onto drum under a load of at least 500lbs. If this
precaution is not taken then the inner wraps will
damage the winch rope.
General
Keep vehicle battery in good condition. Make sure the
winch battery cable are not drawn taut against any
surfaces which could possibly damage them.
Corrosion will reduce performance or may cause a
short. Remove and clean the cable connections to the
battery fuse box and chassis ground periodically. Cover
cables and winch when not in use.
Periodically clean the winch rope with a damp cloth, if
necessary a mild detergent may be used.
Cover winch when not in use.
Page 7
Trouble Shooting
7
Symptom Possible Cause Suggested Remedy
Motor does not turn on
S
witch assembly not connected properlyInsert switch assembly firmly to the connector
Loose battery cable connection Tighten the nuts on the cable connectors
Solenoid malfunctioning
Tap solenoid to free contact, applying 12 volts to
coil terminal directly. The solenoid will make an
audible clicking when activating.
Defective switch assembly Replace switch assembly
Defective motor
Check for voltage at armature port with switch
pressed. If voltage is present then replace motor.
Water has entered motor
Drain and dry. Run in short bursts without load
until completely dry.
Motor runs too hot Long period of operation Let winch cool down periodically
Motor runs slowly or without normal
power
Battery runs down Recharge battery by running vehicle engine
Insufficient current or voltage Clean, tighten or replace the connector
Motor runs but cable drum does not
turn
Clutch (cam ring) not engaged
Push cam ring into IN position. If that does not
work, ask a qualified technician to check and
repair
Motor runs in one direction only
Defective or stuck solenoid
Tap solenoid to free contacts. Repair or replace
solenoid.
Defective switch assembly Replace switch assembly
Britpart
Border Holdings (UK) Ltd
The Grove
Craven Arms
Shropshire
SY7 8DA
United Kingdom
Page 8
Britpart Limited 24 Month Guarantee
GUARANTEE CARD
Tel: +44 (0) 1588 672711
Fax: +44 (0) 1588 672660
Email: [email protected]
www.britpart.com
Britpart
Border Holdings (UK) Ltd
The Grove
Craven Arms
Shropshire
SY7 8DA
United Kingdom
Britpart offers a limited twenty four month guarantee,
to the original retailer purchaser, for each new Britpart
electric winch against manufacturing defects in
workmanship and materials on all mechanical and
electrical components.
New cable assemblies are guaranteed against defects
in workmanship and materials when received by the
retail purchaser. There is no applicable guarantee after
initial use.
Guarantee registration cards for each winch must be
submitted at the time of purchase or within 30 days by
the end user. Guarantee will only be valid for the original
purchaser of the winch and installed on the vehicle for
which it was originally registered.
Britpart electric winches are intended for recreational
self recovery usage. The guarantee is void if the winch is
used in commercial/industrial applications.
The obligation under this guarantee, statutory or
otherwise, is limited to the replacement or repair at the
manufacturers factory or at a point designated by the
manufacturer, of such part(s) as shall appear to the
manufacturer, upon inspection of such part(s), to have
been defective in material or workmanship. This
guarantee does not obligate Britpart to bear the cost of
labour or transportation charges in connection with the
replacement or repair of defective part(s), nor shall it
apply to a product upon which repairs or alterations
have been made, unless authorised by the
manufacturer, or for equipment misused, neglected or
improperly installed.
Important Notice
To the fullest extend permitted by applicable law, the
following are hereby excluded and disclaimed:
1 - All warranties of fitness for a particular purpose
2 - All warranties of merchantability
3
- All claims for consequential or incidental damages
There are no warranties that extend beyond the
description that appears on the face hereof.
To the extent such warranties of fitness or
merchantability are deemed to apply to this product,
they exist for only so long as the express limited
warranty elsewhere set forth is in existence.
Britpart reserves the right to change, alter or improve
its products in design, materials or appearance without
incurring any obligation to incorporate such changes in
products that were previously manufactured.
To submit a guarantee claim contact your Britpart
distributor.
name:
address:
postcode:
telephone number:
Britpart model number:
serial number:
gi number: (found on Britpart sticker on box)
invoice number:
date of invoice:
where did you purchase winch:
who installed your winch:
what vehicle is the winch installed onto -
make:
model:
year:
return completed form to:
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