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ORIGINAL INSTRUCTIONS
Winch and Wireless Remote Control Installation and Operation Guide.
Every winching situation has the potential for personal injury. In order to minimize that risk,
it is important to read this guide carefully. Please familiarize yourself with the operation of
you winch before using it and be constantly safety oriented. In this guide we provide
important safety information and instructions on how to install your winch.
SAVE THIS MANUAL and other product literature found in this kit for future reference and
review frequently for continuing safe operation. Instruct all users of this product to review
this manual before operating this product.
TABLE OF CONTENTS:
SAFETY:
Symbol Index
2
General Safety Precautions
3 - 6
INSTRUCTIONS:
Know Your Winch
7 - 10
Mounting
11
Free Spool Operation
11
Electrical Connections
11 - 12
Know Your Wireless Remote Control
12
Maintenance
13
Trouble Shooting/Error Conditions
14
Disposal
15
CE Declaration of Conformity
16
Page 2
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SYMBOL INDEX
Symbol Index for winch
SYMBOL
EXPLANATION
SYMBOL
EXPLANATION
Read All Product
Literature
Always Wear Leather
Gloves
Always Wear Hearing and
Eye Protection
Do Not Move People
Never Use Winch as a
Hoist
Always Use Supplied
Hook Strap
Properly Seat Load in
Throat of Hook
Never Apply Load to
Hook Tip or Latch
Wind Rope on Bottom of
Drum
Never Wind Rope Over Top
Drum
Finger/Fairlead Crushing
Hazard
Fairlead Pinch Point
Hand Piercing/Cutting
Hazard
Hot Surface Hazard
Explosion/Bursting
Hazard
Fire and Burn Hazard
Never Route Electrical
Cables Across Sharp
Edges
Never Route Electrical
Cables through or Near
Moving Parts
Avoid Installing Electrical
Cables around pinch and
Wear/Abrasion Points
Exposed Wiring Hazard
Insulate Exposed Wiring
And Terminals
Clutch Disengaged
Never Hook Back on
Rope
R i g h t
W r o n g
Avoid
side pulls
R i g h t
W r o n g
Never hook
the wire rope
back onto
itself
Page 3
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GENERAL SAFETY PRECAUTIONS
Warnings and Cautions
As you read these instructions, you will see WARNINGS, CAUTIONS, NOTICES and
NOTES. Each message has a specific Purpose. WARNINGS are safety messages that
indicate a potentially hazardous situation, which, if not avoided could result in serious injury
or death. CAUTIONS are safety messages that indicate a potentially hazardous situation,
which, if not avoided, could result in minor or moderate injury. A CAUTION may also be used
to alert against unsafe practice. CAUTIONS and WARNINGS identify the hazard, indicate
how to avoid the hazard, and advise of the probable consequence of not avoiding the
hazard. NOTICES are messages to avoid property damage. NOTES are additional
information to help you complete a procedure. PLEASE WORK SAFELY!
FCC Regulation
This device complies with Part 15 of the FCC Rule. Operation is subject to the following two
conditions:
This device may not cause harmful interference.
This device must accept any interference received, including interference that may
cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This
equipment generates, uses and can radiate radio frequency energy, and if not installed and
used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following measures:
Reorient or relocate the receiving antenna. Increase the separation between the
equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
Consult the dealer or an experienced radio/TV technician for help.
Page 4
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GENERAL SAFETY PRECAUTIONS
W A R N I N G
W A R N I N G
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to serious
injury or death.
Winching Safety:
1. Always
Know Your Winch. Take time to fully read the
Instructions in Order to understand your winch and its
operations.
2. Never
exceed winch or winch rope rated capacity.
Double line using a snatch block to reduce winch load.
3. Always
wear heavy leather gloves when handling winch
rope.
4. Never
use winch or winch rope for towing. Shock loads
can damage, overload and break rope.
5. Never
use a winch to secure a load.
6. Never
operate this winch when under the influence of
drugs, alcohol or medication
7. Never
operate this winch if you are under 16 years of
age.
Installation Safety:
1.
Always
choose a mounting location that is sufficiently
strong to withstand the maximum pulling capacity of your
winch.
2.
Always
use class8.8 metric (grade 5) or better hardware.
3.
Never
weld mounting bolts.
4.
Always
use factory approved mounting hardware,
components, and accessories.
5.
Never
use bolts that are too long.
6.
Always
confirm required bolt length to ensure proper
thread engagement.
7.
Always
complete the winch installation and hook
attachment before installing the wiring.
8.
Always
keep hands clear of winch rope, hook loop, hook
and fairlead opening during installation, operation, and
when spooling in or out.
9.
Always
position fairlead with warning readily visible on
top.
10.
Always
pre-stretch rope and re-spool under load before
use. Tightly wound rope reduces chances of ”binding”,
which can damage the rope.
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to
serious injury or death.
General Safety:
Always
inspect winch rope, hook, and slings before
operating winch. Frayed, kinked or damaged winch
rope must be replaced immediately. Damaged
components must be replaced before operation.
Protect parts from damage.
Always
remove any element or obstacle that may
interfere with safe operation of the winch.
Always
be certain the anchor you select will
withstand the load and the strap or chain will not slip.
Always
use supplied hook strap whenever spooling
winch rope in or out, during installation and during
operation.
Always
require operators and bystanders to be
aware of vehicle and or load.
Always
be aware of stability of vehicle and load
during winching, keep others away. Alert all
bystanders of an unstable condition.
Always
unspool as much winch rope as possible
when rigging. Double line or pick distant anchor
point.
Always
take time to use appropriate rigging
techniques for a winch pull.
Never
touch winch rope or hook while someone else
is at the control switch or during winching operation.
Never
engage or disengage clutch if winch is under
load, winch rope is in tension or drum is moving.
Never
touch winch rope or hook while under tension
or under load.
Always
stand clear of winch rope and load and keep
others away while winching.
Never
use vehicle to pull load on winch rope.
Combined load or shock load can damage, over load
and break rope.
Never
wrap winch rope back onto itself. Use a
choker chain or tree trunk protector on the anchor.
Never
use remote when vehicle is not in line of sight
of operator.
Never
pair more than one winch and one remote
together at the same time.
Page 5
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GENERAL SAFETY PRECAUTIONS
W A R N I N G
W A R N I N G
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to serious
injury or death.
Always
ensure hook latch is closed and not supporting
load.
Never
apply load to hook tip or latch. Apply load only to the
center of hook.
Never
use a hook whose throat opening has increased, or
whose tip is bent or twisted.
Always
use a hook with a latch.
Always
ensure the operator and bystanders are aware of
the stability of the vehicle and/or load.
Never
hook back on rope.
FALLING OR CRUSHING HAZARD
Failure to observe these instructions could lead to
serious injury or death.
Always
stand clear, keep hands clear, and keep
others away.
Never
operate winch with less than 5wraps of wire
rope/10wraps of synthetic rope around the drum.
Rope could come loose from the drum, as the rope
attachment to the drum is not designed to hold a load.
Never
use winch as a hoist or to suspend a load.
Always
be certain anchor will withstand load, use
appropriate rigging and take time to rig correctly.
Never
use winch to lift or move persons.
Never
use excessive effort to free spool winch rope.
Always
use proper posture/lifting technique or get
lifting assistance while handling and installing
product.
Always
wind the winch rope on bottom (mount side)
of drum.
Never
wind rope over top of drum.
Always
spool the winch rope onto the drum in the
direction specified by the drum rotation labels on the
winch and/or in the documentation. This is required
for the automatic brake (if so equipped) to function
properly.
W ARN IN G
CHEMICAL AND FIRE HAZARD
Failure to observe these instructions could lead to serious
injury or death.
Always
remove jewelry and wear eye protection.
Never
route electrical cables across sharp edges.
Never
route electrical cables near parts that get hot.
Never
route electrical cables through or near moving parts.
Always
place the supplied terminal boots on wires and
terminals as directed by the installation instructions.
Never
lean over battery while making connections.
Never
route electrical cables over battery terminals.
Never
short batter terminals with metal objects.
Always
consult operator’s manual for proper wiring details.
Always
insulate and protect all exposed wiring and
electrical terminals.
Always
connect red (+) power cable ONLY to the positive
(+) terminal of the battery.
Always
connect black ground (-) power cable ONLY to the
negative (-) terminal of the battery.
Never
connect red (+) power cable to the negative (-)
terminal of the battery.
WA RN I NG
CUT AND BURN HAZARD
Failure to observe these instructions could lead to
serious injury or death.
To avoid injury to hands and fingers:
Always
wear heavy leather gloves when handling
winch rope.
Always
be aware of possible hot surfaces at winch
motor, drum or rope during or after winch use.
Page 6
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GENERAL SAFETY PRECAUTIONS
C A U T I O N
C A U T I O N
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to serious
injury or death.
To avoid injury to hands and fingers:
Never
leave winch remote control where it can be
activated during free spooling, ringing, or when the winch
is not being used.
Never
leave the wireless winch remote control turned on
when installing, free spooling, rigging or servicing winch,
or when the winch is not being used.
CUT AND BURN HAZARD
Failure to observe these instructions could lead to
minor or moderate injury.
Never
let winch rope slip through your hands.
This manual provides instructions on how to install and operate your winch and operating
your Wireless Remote Control.
SAFETY
When installing your winch system, read and follow all mounting and safety instructions.
Always use caution when working with electricity and remember to verify that no exposed
electrical connections exist before energizing your winch circuit.
For specifications and performance data, refer to the specification sheet supplied in this
manual.
NO TI C E
NO TI C E
R i g h t
W r o n g
R i g h t
W r o n g
AVOID WINCH AND EQUIPMENT DAMAGE
Always
avoid side pulls which can pile up winch rope at
one end of the drum. This can damage winch rope or
winch.
Always
ensure the clutch is fully engaged or disengaged.
Always
use care to not damage the vehicle frame when
anchoring to a vehicle during a winching operation.
Never
submerge winch in water, if not IP68 rated.
Always
store the remote control in a protected, clean dry
area.
Never hook the wire rope back onto itself
because you could damage the wire rope .Use a
strap.
Avoid continuous pulls from extreme angles as
this will cause the wire rope to pile up on one
end of the drum. This can jam the can jam the
wire rope of the winch.
Page 7
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KNOW YOUR WINCH
Before you begin, you should familiarize yourself with your winch and each of its
components;
3000lb Winch Specifications
Rated Line Pull: 3000lbs (1361kg)
Motor: 12V DC 3.0HP/2.24KW Permanent Magnet Motor
Controls: Remote Control (Handlebar) & Wireless Remote Control
Gear train: 1-Stage Planetary
Gear Ration: 153:1
Clutch (Free Spool): Pull and Push
Drum diameter/length: 1.5” /2.83” (38mm/72mm)
Rope: Galvanized Steel Wire 3/16” x42.6’ (4.76mm x 13m)
Recommended Battery: 12 Amp/hr. minimum
Fairlead: Roller
Duty Cycle: Intermittent
Mounting Bolt Pattern: 3.15” (80mm)
Winch Dimensions: 11.7＂Lx4.65＂Wx4.21＂H(297mm x 118mm x 107mm)
Shipping Weight: 19.4lbs(8.8kgs)
LINE PULL AND ROPE CAPACITY LAYER
Layer of cable
1 2 3 4 5
Rated line pull
Lbs
3000
2420
2027
1740
1053
Kgs
1361
1097
919
789
694
Cable of layer
Ft
6.14
13.8
22.83
33.4
42.7
M
1.87
4.21
6.96
10.19
13
LINE SPEED & AMP DRAW – FIRST LAYER
Line pull
Lbs 0 1000
2000
3000
Kgs
0
453.6
907
1361
Line Speed
Fpm
13.82
8.6
7.19
5.9
Mpm
4.21
2.62
2.19
1.8
Amp
A
11
65
110
150
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KNOW YOUR WINCH
No.
Name
Qty
No.
Name
Qty
1
Motor assembly
1
15
M6*16 inside hexagonal bolt
2 2 Inner gear
1
16
Clutch handle
1
3
Planetary gear
1
17
Plug pin
1
4
Inner gear plate
1
18
M5*10 round head screw
2
5
Clutch gear
1
19
M8*16 hexagon head screw
2
6
Clutch spring
1
20
Wire rope assembly
1
7
Clutch bar
1
21
M5*12 hexagon head screw
2
8
Gear box cover
1
22
Hook
1
9
Free bearing
1
23
Hook belt
1
10
Drum
1
24
Wired remote handle
1
11
Support bar
2
25
Control box assembly
1
12
Free bearing
1
26
Wireless remote handle
2
13
Elastic steel plate
1
27
Wire cord sheath
2
14
M5 flange nut
2
Page 9
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KNOW YOUR WINCH
4500lb Specifications
Rated Line Pull: 4500lbs(2041kg)
Motor: 12V DC 3.9HP/2.9KW Permanent Magnet Motor
Controls: Remote Control & Wireless Remote Control
Gear train: 2-Stage Planetary
Gear Ration: 271:1
Clutch (Free spool): Rotate 105°
Drum diameter/length: 1.97＂/2.83＂(50mm /115mm)
Rope: Galvanized Steel Wire 0.26＂x49.2＇(6.5mm x 15m)
Recommended Battery: 12 Amp/hr minimum
Fairlead: Roller
Duty Cycle: Intermittent
Mounting Bolt Pattern: 2.99＂x6.49＂(76mm x165mm)
Winch Dimensions: 13.77＂Lx4.53＂Wx4.72＂H(350mm x 115mm x 120mm)
Shipping Weight: 33lbs(15kgs)
LINE PULL AND ROPE CAPACITY LAYER
Layer of cable
1 2 3 4
Rated line pull
Lbs
4500
3879
3214
2812
Kgs
2041
1759
1457
1275
Cable of layer
Ft
12.47
21.98
39.37
49.21
M
3.8
6.7
12
15
LINE SPEED & AMP DRAW-FIRST LAYER
Line pull
Lbs 0 1000
2000
4500
Kgs 0 453.6
907
2041
Line Speed
Fpm
13.7
11.48
9.2
7.87
Mpm
4.2
3.5
2.81
2.4
Amp
A
45
87
120
170
Page 10
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KNOW YOUR WINCH
No
Name
Qty
No
Name
Qty
No
Name
Qt
y
1
M6*16 inside
hexagonal bolt
4
14
1st stage planetary
gear
1 27
Hexagon screw
M8*25
2
2
Motor
assembly
1
15
Inner gear
1 28
Φ8 flat washer
2
3
Shaft coupling
1
16
Block ring 24*1.2
1
29
Φ8 spring washer
2
4
Free bearing
2
17
Gear box
1 30
M8 lock nut
2
5
O ring sealing
2
18
Clutch handle
1 31
Hook belt
1
6
Drum
1
19
Wire rope
assembly
1 32
M8*20 inside
hexagonal bolt
4
7
Support bar
2
20
Clutch spring
1
33
Hook 5/16”
1
8
Transmission
shaft
1
21
1
st
stage inner gear
1
34
Control box
assembly
1
9
Clutch gear
1
22
Triangles slider
1
35
Wired remote
handle
1
10
Gear box cover
1
23
O ring
Φ104*1.8
1
36
Battery wire cord
2
11
Inner gear plate
1
24
O ring
Φ24*1.5
1
37
Motor wire cord
2
12
2nd stage
planetary gear
1
25
Mounting plate
1
38
Wireless remote
handle
2
13
Planetary gear
spacer
2 26
Fairlead
1
39
Wire cord sheath
4
Page 11
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MOUNTING
To prevent accidental activation of the winch and serious injury, complete the winch installation and
attach the hook before installing the wiring.
Always choose a mounting location that is sufficiently strong enough to withstand the maximum pulling
capacity of your winch.
Always spool the winch rope onto the drum in the direction specified by the drum rotation labels on the
winch and/or in the documentation. This is required for the automatic brake (if so equipped) to function properly.
Always wind the winch rope on the bottom (mount side) of the drum.
This winch should always be mounted in a horizontal orientation with the rope winding on and off the drum on the
mount side (bottom) of the drum.
Correct rotation is required for the automatic brake to function properly. Horizontal mounting helps prevent the rope
from piling up on one end of the drum which can damage the winch.
FREESPOOL OPERATION
Pull and turn the clutch knob to the “Free spool” position. Activate the winch in Cable Out to check the drum rotation
direction. If the drum rotates in the wrong direction, recheck your wiring. If there is a load on the rope, the clutch
knob may not pull out easily. DO NOT FORCE THE CLUTCH KNOB. Release tension on the clutch by jogging out
some of the rope. Check that there are at least five turns of wire rope/ ten turns of synthetic rope left on the drum.
Re-engaged the drum by returning the clutch knob to the “Engaged” position. Different winches with different
clutches as the followed figures, you shall make sure which one fit to your winch.
ATV winch
Clutch Free spool Operation
Caution
Pull and
push
1
2
Engaged
Clutch must be fully
engaged before
winching.
Never engage clutch
knob while drum is
turning.
If the winch motor
stalls, do not
continue to apply
power.
Rotate
Engaged
Freespool
ELECTRICAL CONNECTIONS
Refer to the figures for wiring diagram. Different winches with different wiring diagram, you
shall make sure which one fit to your winch.
Page 12
Page 13
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MAINTENANCE
Check
Before first
operation
After each
use
Every 90
days
Take time to fully read the Instructions. in order
to understand your winch and its operations
√
Check fasteners and make sure they are tight
and to proper torque. Replace damaged
fasteners.
√
√ Verify wiring to all components is correct and be
certain that all connections are tight.
√
√
Verify there is no exposed/bare wiring. Terminals
or cable insulation damage (chafing/cutting).
Cover any exposures with terminal boots. Repair
or replace damaged electrical cable.
√
√
Inspect rope for damage. Replace rope
immediately if damaged.
√ √ √
Keep winch, rope and switch control free from
contaminants. Use a clean rag or towel to
remove any dirt and debris.
√
Check and place/replace the battery of wireless
remote control
√ √
Turn off the power after use
√ √
Page 14
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TROUBLE SHOOTING
Trouble Shooting/Error Conditions
When the winch fails to operate after several attempts, or if there is any fault operation while
winching. Check followings.
Symptom
Possible cause
Remedy
Winch will
not
operate
Cut Circuit or loosing
Check battery cable
The remote battery is critically low
Replace or charge battery
Wireless signal strength is low
Decrease distance between remote
control and winch.
Damaged over load protector
Replace over load protector
Loose connection of wirings
Checking all wirings
Damaged or stuck solenoid
Replace solenoid
Defective remote control
Check winch operation with an auxiliary
switch
Damaged motor or worn carbon
brush
Replace motor or carbon brush
Winch control pack is Under
water. Wireless signal will not
transmit under water
Winch control pack needs to be above
water to receive wireless signal.
Motor runs
in one
direction
Broken wiring or bad connection
Reconnect or replace wiring
Damaged or stuck solenoid
Replace solenoid
Switch inoperative
Replace switch
Dropt or lost wiring
Replace wiring and tighten
Drum will
not free
spool
Frees pool not dis-engaged
Disengaged frees pool
Damaged brake or frees pool
assembly
Replace brake or frees pool assembly
Damaged gear box
Replace gear box
No brake
Damaged on inoperative pressed
spring
Replace pressed spring
Disengaged free spool
Engaged free spool
Damaged inner gear plate
Replace inner gear plate
Damaged inner gear
Replace inner gear
Winch runs
opposite
direction
Motor leads crossed
Reverse electric connections to motor
Solenoid control crossed
Reverse black and red wires on
solenoid
Remote control or trigger switch
crossed
Reverse electric connections
Motor runs
extremely
hot
Long period of operation
Stop operation and make it cool
Over load
Reduce load
Damaged or inoperative of brake
Replace or repair the brake
Page 15
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DISPOSAL
Batteries should not be disposed of in general household waste. Observe the local waste disposal regulations,
details of which can be obtained from your local authority.
All electrical and electronic equipment must be disposed of separately from general household waste using the
sites designated by local authorities.
If a product displays this symbol of a crossed-out wheelie bin, the product is subject to European Directive
2012/19/EC.
The appropriate disposal and separate collection of used equipment serve to prevent potential harm to the
environment and health. They are a prerequisite for the re-use and recycling of used electrical and electronic
equipment.
For further information on disposing of your used equipment, please contact your local authority or your refuse
collection service.
Page 16
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CE DECLARATION OF CONFORMITY
We hereby declare that the machine described below complies with the relevant basic safety and health
requirements of the EU Directives, both in its basic design and construction as well as in the version put into
circulation by us. This declaration shall cease to be valid if the machine is modified without our prior approval.
The undersigned: Michael S McQuaide
as authorised by: Union Mart Ltd
Declares that
Description: 12V Electric Winch
Identification code: Rhino Winch 3000lb & 4500lb
Conforms to the following directives and standards:
• Machinery Directive 2006/42/EC
• EMC Directive 2004/108/EC
• RoHS Directive 2011/65/EU
• 2014/30/EU Electromagnetic Compatibility
• 2014/53/EU EC-RED Directive
--
• EN 61000-6-1:2007
• EN 61000-6-3:2007+A1:2011
• EN 61000-3-2:2006+A1:2009+A2:2009
• EN 61000-3-3:2008
• EN ISO 12100:2010
• EN 14492-1:2006+A1:2009
Notified body: ENTE CERTIFICAZIONE MACCHINE SRL
The technical documentation is kept by: Union Mart Ltd
Date: 01/01/17
Signed:
Michael S McQuaide
Managing Director
Name and address of the manufacturer:
Union Mart Ltd, Company No. 8384155. Registered address: Unit C3,
Deacon Trading Estate, Chicken Hall Ln, Eastleigh SO50 6RS, United Kingdom.
Page 17
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