Smittybilt 97203 User Manual
WWW.SMITTYBILT.COM
XRC 3.0 3,0001b Winch
Part # 97203
WWW.SMITTYBILT.COM
XRC 3.0 3,0001b Winch
Part # 97203
Table of contents:
Winch Packing List...................................................02
Safety Warnings & Precautions.................................02
Installation...............................................................08
Mount the Winch....................................................08
Mount the Contactor or Control Box.......................09
Mount the Handlebar Switch...................................11
Mount the Connector for Remote ...........................12
Install the Wiring....................................................12
Check the System..................................................14
Winch Maintenance &Troubleshooting.....................14
Winch Assembly Drawing.........................................16
Winch Parts List.......................................................17
Winch Specification.................................................18
Winch Packing List
DESCRIPTION QUANTITY
1.Winch Assembly with Wire Rope ....................1
2.Cap Bolt M8* 30 .............................................2
3.Lock Washers ...............................................2
4.Flat Washers........................................ .........2
5.M8 Nuts.........................................................2
6.Clevis Hook w/Pin .........................................1
7. ................................1
Handle Bar Control
8.Strap ............................................................1
9.Remote........................................................1
10.Winch Plate................................................1
11.Solenoid..........................................................1
Warnings and Cautions
XRC3.0 (3000lbs) WINCH........................................18
Warranty............................................................19
Warranty Information Card..........................................20
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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 avo ided coul d res ult in ser ious injur y
or death. CAUTIONS are safety messages that indicate a potentially hazardous
situation which, if not avoided, could result in minor or moderate inju ry. 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!
XRC 3.0 3,0001b Winch
WWW.SMITTYBILT.COM
Part # 97203
MOVING PARTS ENTANGLEMENTHAZARD
Failure to observe these instructions could lead to severe injury or death.To avoid
injury to hands or fingers:
Always keep han ds clear of ro pe, hook loop, hook and fairlead opening during
installation, operation and when spooling in or out.
Always use extreme caution when handling hook and rope during spooling
operations.
Always use supplied hook strap whenever spooling rope in or out, during in
stallation, and during operation.
Always keep vehicle in sight during winching operation.
Always wear heavy leather gloves when handling rope.
CHEMICAL AND FIRE HAZARD
Failure to observe these instructions could lead to severe injury or death.
Always remove jewelry and wear eye protection.
Never lean over battery while making connections.
Always verify area is clear of fuel lines, fuel tank, brake lines,electrical wires, etc.
When drilling.
Never route electrical cables:
- Across any sharp edges.
- Through or near moving parts.
- Near parts that become hot.
Always insulate and protect all exposed wiring and electrical terminals.
Always install terminal boots as directed in installation instructions.
XRC 3.0 3,0001b Winch
WWW.SMITTYBILT.COM
Part # 97203
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could lead to minor or moderate injury.
Always keep wired remote control lead clear of the drum, rope and rigging.
Inspect for cracks, pinches, frayed wires or loose connections. Replace remote
control if damaged.
Always pass wired remote control through a window to avoid pinching lead in door,
when using remote inside a vehicle.
Never leave remote control where it can be activated during freespooling, ri gging, or
when the winch is not being used.
Always require operator and bystanders to be aware of vehicle and or load.
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could lead to minor or moderate injury. General
Safety:
Always know your winch. Take time to fully read the Installation Guide and the Basic
Guide to Winching Techniques in order to understand your winch and its operation.
Never operate this winch if you are under 16 years of age.
Never operate this winch when under the influence of drugs, alcohol or medication.
Never exceed winch or rope capacity listed on product data sheet. Double line
using a snatch block to reduce winch load.Installation Safety:
Always choose a mounting location that is sufficiently strong to withstand the
maximum pulling capacity of your winch.
Always use factory approved mounting hardware, components, and
accessories.
Always use grade 5 (grade 8.8 metric) or better mounting hardware.
Never weld mounting bolts.
Always use care when using longer bolts than those supplied from factory. Bolts
that are too long can damage the base and/or prevent the winch from being mounted
securely.
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XRC 3.0 3,0001b Winch
WWW.SMITTYBILT.COM
Part # 97203
Always mount the winch and attach the hook to the rope`s end loop before conne cting
the electrical wiring.
Always spool the rope onto the drum in the direction specified by the winch warning label
on the winch and/or documentation. This is required for the automatic brake (if so
equipped) to function properly.
Always prestretch wire rope and respool under load before use. Tightly wound wire
rope reduces chances of binding , which can damage the rope.
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could lead to minor or moderate injury.
Always inspect, rope, hook, and slings before operating w inch. Fra yed, kink ed or
damaged rope must be replaced immediately. Damaged components must be re pla ced
before operation. Protect parts from damage.
Never leave remote control plugged into winch when free spooling, rigging, or
when the winch is not being used.
Never hook rope back onto itself. This damages the rope.
Always use a choker chain, choke r ro pe, or tr ee tru nk pro tecto r on the anchor.
Always remove any element or obstacle that may interfere with safe operation
of the winch.
Always take time to u se appropriate rigging techniques for a winch pull.
Always be certain the anchor you select will withstand the load and the strap or chain
will not slip.
Never engage or disengage clutch if winch is under load, rope is in tension or drum is
moving.
Always select an anchor point as far away as possible. This will provide the winch
with its greatest pulling power.
Never winch with less than 5 wraps of rope around the drum. The rope could come
loose from the drum.
Never touch rope or hook while in tension or under load.
Never touch rope or hook while someone else is at the control switch or during
winching operation.
Always stand clear of rope and load and keep others away while winching.
Always be aware of stability of vehicle and load during winching, keep others away.
Alert all bystanders of any unstable condition.
Never use winch to secure a load.
XRC 3.0 3,0001b Winch
WWW.SMITTYBILT.COM
Part # 97203
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could lead to minor to moderate injury.
Always use a hook with a latch
Always insure 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.
FALLING OR CRUSHING HAZARD
Failure to observe these instructions could lead to severe injury or death.
Never use winch to lift or move persons.
Never use winch as a hoist or to suspend a load.
CUT AND BURN HAZARD
Failure to observe these instructions could lead to minor or moderate injury.
To avoid injury to hands and fingers:
Always wear heavy leather gloves when handling a rope.
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