Mile Marker PE4500 ES, SEC8 ES, SEC8 Scout ES, SEC12 ES, SEC15 ES Installation And Operator's Manual
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Installation and Operator’s Manual:
Project ES Winch System:
Table of Contents:
Safety Warnings & Precautions..........................3
inching Tips & Techniques...............................6
W
Getting Started:
Unpacking Your Winch............................8
Winch Mounting.....................................8
Clocking Instructions.........................................9
Control Box Installation....................................10
inch Operation..............................................14
W
Maintenance...................................................15
Troubleshooting...............................................15
Features.........................................................16
Parts Lists.....................................................19
Warranty........................................................25
2
Safety Warnings
When using this winch, safety precautions should always be followed
to reduce the risk of personal injury and damage to the winch.
1) LEARN TO USE YOUR MILE MARKER WINCH:
a. After winch has been installed, take some time and
practice using it so you will be familiar with ALL OPERATIONS. Periodically check the winch installation to ensure
that all bolts are tight.
b. To ensure proper operation, carefully inspect for
any damaged parts before operating the winch.
2) 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. Due to the possibility of cable failure, direct all
personnel to stand clear of any possible pathway. A snapped
cable could cause winch failure, injury or death. Keep proper
footing and balance at all times. Do not reach over or across
the winch and/or pulling cable while the winch is in operation.
3) INSPECT WIRE ROPE AND EQUIPMENT FREQUENTLY:
The wire rope should be inspected for damage that could
reduce it’s breaking strength. A frayed rope with broken
strands should be replaced immediately. Always replace the
rope with a rope that is rated to sustain any load that the
winch is capable of pulling. Any substitute must be IDENTICAL in strength, quality, lay and stranding to the Mile Marker
cable originally supplied.
4) WORKING AREA CONDITIONS:
Keep the working area well lit. Do not use this winch in the
presence of flammable gases or liquids.
5) KEEP CHILDREN AWAY:
Keep children away from working area. Never let children
operate the winch.
6) DRESS PROPERLY:
Do not wear loose clothing or jewelry as they can be caught
in moving parts. Protective, electrically non-conductive
clothes and non-skid footwear is the only type of clothing you
should be using when operating the winch. Wear restrictive
hair covering to contain long hair.
7) USE LEATHER GLOVES:
When handling or rewinding wire rope always use hand protection to eliminate the possibility of cuts caused by burrs &
slivers from broken strands.
8) DRUM ROPE:
Always make sure that there are at least 5 complete turns of
rope left on the drum before winching.
9) KEEP HANDS AND FINGERS CLEAR OF WIRE
ROPE AND HOOK WHEN OPERATING WINCH:
Never put your finger through the hook when reeling in the
last few feet. If your finger should become trapped in the
hook or rope, you could lose your finger. Never guide a wire
rope under tension onto the drum with your hand.
10) NEVER HOOK THE ROPE BACK ONTO ITSELF:
Hooking the rope back onto itself creates an excessive strain
that could break individual strands; this, in effect, weakens
the entire wire rope.
11) 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 more than
one minute at or near rated load. If the motor becomes too
hot to touch, stop and let it cool off for a few minutes. If the
motor stalls, cut off the power immediately.
3
Safety Warnings-Cont’d
When using this winch, safety precautions should always be followed
to reduce the risk of personal injury and damage to the winch.
12) DO NOT OVERLOAD:
For your safety and efficient performance, always use this
winch at or under its rated capacity for your safety and for
better performance. Do not use inappropriate attachments
in an attempt to exceed its rated capacity.
13) AVOID CONTINUOUS PULLS FROM EXTREME
ANGLES:
This will cause the rope to pile up at one end of the drum.
When possible, please get the rope as straight as possible to
the direction of the object.
14) NEVER OPERATE THE WINCH WITHOUT THE
ROPE FAIRLEAD FITTED:
Operator injury or winch damage can result if a fairlead is
not installed.
15) STAY ALERT:
Watch what you are doing. Use your common sense. Do
not use this winch when you are tired, stressed or WHEN
UNDER THE INFLUENCE OF DRUGS, ALCOHOL OR MEDICATION.
16) DISCONNECT REMOTE CONTROL:
Unplug the winch’s remote control when not in use.
17) REPLACEMENT PARTS & ACCESSORIES:
When servicing, use only identical replacement parts.
Usage of any other parts will void the warranty. Approved
accessories are available from your local distributor.
4
Precautions
When using this winch, safety precautions should always be followed
to reduce the risk of personal injury and damage to the winch.
1) Keeps hands and body away from Fairlead (cable
intake slot) when operating.
2) Secure vehicle in position before using winch.
3) Do not exceed winch load weight capacity (see
Winch Specifications).
4) Be certain winch is properly bolted to a structure
(or vehicle) that can hold the winch load.
5) Always use proper couplings when connecting
winch cable hook to load.
6) Do not lift items vertically. The winch was designed
for horizontal use only.
7) Do not overload the winch (see Model Specifications). It will do the job better at the load it was intended.
8) Do not use inappropriate attachments to extend the
length of the winch cable.
11) Do not apply load to winch when cable is fully
extended. Keep AT LEAST 5 FULL TURNS of cable on the
drum.
12) After moving an item with the winch, secure the
item. Do not rely on the winch to hold it for an extended period.
13) Examine winch before using. Components may be
affected by exposure to everyday weathering, chemicals,
salts, and rust.
14) When loading a boat into a trailer without reel or
side hull rollers, make sure the trailer is submerged in the
water when the boat is loaded by the winch. Attempting to
drag the boat on to the trailer while on land can cause winch
failure and possible injury.
15) Never operate winch if cable shows any signs of
weakening, is knotted or kinked.
16) Do not cross over or under the cable while it is in
process of loading.
9) NEVER LIFT PEOPLE OR HOIST LOADS OVER
PEOPLE.
10) Never come in between the winch and the load
when operating.
17) Do not move vehicle with cable extended and attached to load to pull it. The cable could snap.
18) Apply blocks (such as a wheel choke) to vehicle
when parked on an incline.
19) Re-spool cable properly.
5
Winching Tips & Techniques
WINCHING TIPS AND USE OF A SNATCH BLOCK
•Use OEM tow hooks, recovery eyes or a clevis mount for attachment of a tow strap or winch cable. Warning: Never use a ball and
/or ball mount as an anchor point for tow strap or winch cable.
Severe personal injury or death could occur.
•Always heed all winch manufacturer’s recommendations, cautions, and warnings.
•Attach return cable to tow hook or recovery eye when using a
snatch block. Always use a clevis to secure snatch block to strap,
or severe damage could occur to persons and vehicle. (See Figure
Below). Caution: Never attach return cable to winch mount. This
may overload winch mount and/or front receiver.
RATING
For maximum line pull rating, winch cable direction must not
exceed:
1. 15º angle up or down from horizontal (See Figure Below).
2. 45º angle left or right from straight ahead (See Figure Below).
Caution: Exceeding the maximum line pull rating may overload
winch, winch mount, and/or front mounted receiver.
SAFETY TIPS
•NEVER DISENGAGE CLUTCH LEVER WHEN THERE IS A
LOAD ON THE WINCH. Mile Marker electric winches utilize
an automatic load holding brake, therefore no adjustment to
clutch is needed to maintain load.
•Store the remote control cord in a safe place when not in use
to prevent use by children or other unauthorized persons who
could injure themselves or others or damage the controls.
•Do not operate winch inder the influence of drugs, alcohol,
or medications.
•Isolate winch before putting hands in or around the fairlead
or wire rope drum (The Danger Zone).
•DO NOT OVERLOAD YOUR WINCH. Do not maintain power to
the winch if the drum stops. Overloads can damage the vehicle,
winch or winch rope and create unstable operating conditions.
•It is recommended to lay a heavy blanket or jacket over the
rope about halfway along to the hook attachment. If a rope failure should occur, the weight of the cloth will act as a damper
and help prevent the broken rope from whipping (See Figure
Below). Remember to move the blanket or jacket as winching
proceeds, but halt winching when doing so. Partially raising
the hood of the vehicle will also give a measure of protection
to its occupants from broken rope or cable, consistent with sufficient forward visibility for the operator.
6
Winching Tips & Techniques
SELF-RECOVERY
1. Always attempt to get the cable as straight as possible to the direction of the vehicle. It is acceptable to start a pull at an angle if it is
obvious that the vehicle will turn towards the hook anchoring point.
Turning the steering wheel will assist the process. It is recommended
that the driver is in the vehicle.
2. Make sure hand brake and foot brake are free and that the transmission is in neutral.
3. When the driver’s attempt to regain vehicle traction is successful,
he or she should be careful not to overrun the cable and risk the possibility of it being trapped under the vehicle.
4. DO NOT move your vehicle in reverse to assist the winch. The combination of the winch and vehicle pulling together could overload the
cable and winch itself.
USE OF A PULLEY BLOCK OR SNATCH BLOCK
Vehicle self-recovery using the pulley block attached to the anchor
point for direct pull. In this instance the vehicle becomes the “load”
and the actual pulling power on the vehicle will be double at half
winch rope speed. Never connect wire rope or hook back to winch
mount!
Below: Indirect pull necessitated by obstructions or soft
ground. Pulley block attached to load using a suitable anchor
point. Note the angled direction taken by the load and subsequent angle of rope feed-back on the winch drum (extreme
example shown). There may be unavoidable circumstances
requiring this mode, though in general it is not recommended unless applied in stages by moving the anchor point or
vehicle to avoid the sharp angled rewind on the winch drum.
The actual load pulling power and rope speed will depreciate
with any increased angle between the ropes.
The anchor point, when used must be secure, using a tree,
another vehicle or any firm structure to which a pulley block
can be used to your advantage.
Below: Direct pull on load using the winch vehicles as the anchor with
pulley block attached to the load.
The most important aid to successful winching (after the winch) is
the pulley block, which can be used to increase the pulling power
of the winch of for indirect pulls. Pulley blocks can be used in two
modes. First mode is attached to the load and second is secured to
an anchor point.
USE OF A NYLON SLING AND SHACKLE
•A shackle should always be used when attaching winch
hooks to nylon slings. NOTE: The shackle must pass through
both eyes of the sling. The safe working load of the nylon
sling is based on the use of both eye ends.
Never use the cable or hook to connect directly to the nylon
sling.
USE OF GLOVES
•When handling or rewinding the cable always use gloves
to eliminate the possibility of cuts caused by burrs and broken strands. Inspect cable and equipment frequently. The
cable should be replaced immediately if any sign of burrs
or broken strands are evident. A frayed cable with broken
strands should be replaced immediately. Always replace the
cable with a Mile Marker recommended replacement part.
Any substitution must be IDENTICAL in strength, quality, lay
and stranding. Never hook the cable back onto itself. Hooking the cable back onto itself creates an unacceptable strain,
breaking individual strands which in turn weakens the entire cable. Use a sling. Avoid continuous pulls from extreme
angles as this causes cable to pile up at one end of the drum.
7
Getting Started
Unpacking Your Winch
•Unpack your new Mile Marker winch and ensure that all the parts are included by referring to parts list and exploded view
drawings provided in this manual.
NOTE: If you find any missing or broken parts, please call Mile Marker as soon as possible at the number present on the cover
page of this manual.
Winch Mounting
NOTE: Mile Marker recommends the use of its mounting systems for proper winch installation and optimum winch perfor-
mance. However, when not using Mile Marker Mounting System, ensure that the mounting platform is strong enough to meet
the maximum rated load of the winch in use. Mile Marker recommends steel plates with thickness of at least 0.25”.
Your Winch should be aligned and secured to a solid part of the vehicle (front or rear) where the full rated load will be evenly
distributed.
CAUTION: It is essential that the mounting surface be flat and the winch is mounted such that the three major sections (Gear
housing end, drum and motor end) are in proper alignment.
1. Drill four mounting holes (10mm in Dia.), if necessary, according to the bolt pattern mentioned in the winch specifications.
2. Fasten the winch body to the mounting platform using the four Capscrews (M10 X 34mm) and Nuts (M10) provided.
3. Torque the Capscrews to about 35 ft-lb (47.5 N-m).
4. All Mile Marker Mounting Systems come predrilled with fairlead holes. If you are using any other mounting platforms, drill
two holes for the roller fairlead installation. Position the holes such that the fairlead opening hole stretches from the circumference of the drum to the end of the maximum permissible layers on the drum in the direction cable is being rolled.
CAUTION: When replacing the capscrews or when longer bolts are required, make sure that you use bolts of Grade 5 or greater.
8
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