Superwinch C Series, 03000, 03001, 03003, 03002 Owner's Manual

...
VALABLE A TRAVERS LE MONDE GARANTIE LIMITÉE. Superwinch, Inc. (le “Vendeur”) garantit à l’acheteur d’origine (“vous”) que toutes les pièces et composants, à l’exception du câble métallique, sont sans vice de matériaux ou de fabrication, et ce, pendant une période d’un (1) an à compter de la date d’achat prouvable. Tout produit Superwinch défectueux sera réparé ou remplacé sans dépenses de votre part si vous respectez ces procédures. Les garanties énoncées par les présentes sont exclusives tiennent lieu de toutes autres garanties expresses ou implicites. PROCÉDURE DE RECOURS À LA GARANTIE LIMITEE. Dès découverte d’un produit Superwinch défectueux, vous devrez envoyer à Superwinch, à l’usine ou à un Centre de réparation autorisé par l’usine, une notification écrite dudit défaut et vous devrez envoyer par courrier ou autre service de livraison le Superwinch défectueux, port et frais postaux payés à l’avance. Les réparations ou remplacements par le Vendeur conformément à la présente Garantie s’effectueront normalement dans les quinze (15) jours ouvrables suivant récep­tion du Superwinch défectueux. Le Vendeur ou ses Agents autorisés peut facturer des frais raisonnables pour les pièces et la main d’oeuvre en cas de réparation non couverte par la présente Garantie limitée. LIMITATIONS ET EXCLUSIONS EN CE QUI CONCERNE LA GARANTIE ET LES REMÈDES. La réparation et/ou le remplacement de tout Superwinch défectueux ou de tout composant d’un tel Superwinch tel que convenu par les présentes est votre remède exclusif. Les exclusions et limita­tions de garanties et les limitations de REMEDES ci-dessous seront expressément applicables : A. Garanties expresses . Le Vendeur garantit que le Superwinch est tel qu’il est décrit dans le “Mode d’emploi Superwinch” fourni avec la présente; aucune autre garantie expresse n’est don­née en ce qui concerne le Superwinch. Si un modèle ou échantillon vous a été montRé, ledit mod­èle ou échantillon a été utilisé à des fins d’illustration uniquement et ne sera pas considéré une garantie que le Superwinch sera conforme au modèle ou à l’échantillon. LE VENDEUR NE DONNE AUCUNE GARANTIE EXPRESSE EN CE QUI CONCERNE LE CABLE MÉTALLIQUE INCORPORÉ AU PRO­DUIT. B. Garantie implicite . LA GARANTIE IMPLICITE DE L’APTITUDE À LA VENTE ET TOUTE AUTRE GARANTIE IMPLICITE S’APPLIQUERA UNIQUEMENT POUR UNE DURÉE D’UN (1) AN À COMPTER DE LA DATE D’ACHAT PROUVABLE. LE CABLE MÉTALLIQUE EST VENDU “TEL QUEL” SANS AUTRE GARANTIE IMPLICITE. CERTAINS ÉTATS AMÉRICAINS NE PERMETTENT PAS DE LIMITER LA DURÉE DES GARANTIES IMPLICITES; IL EST DONC POSSIBLE QUE LA LIMITATION CI-DESSUS NE S’APPLIQUE PAS À VOTRE CAS. C. Dommages indirects. SUJET AUX OBLIGATIONS DE LA GARANTIE LIMITÉE DU VENDEUR ÉNONCÉES DANS LE PRÉSENT DOCUMENT, LE VENDEUR NE SERA AUCUNEMENT RESPONSABLE DE DOMMAGES INDIRECTS, DE QUELQUE NATURE QUE CE SOIT, NI DE DOMMAGES INDIRECTS À LA PROPRIÉTÉ, NI DE PERTES DE PROFITS, NI DE PERTES D’UTILISATION POUVANT SURVENIR À CAUSE D’UN DÉFAUT, D’UN MAUVAIS FONCTIONNEMENT OU D’UNE PANNE QUELCONQUE DU SUPER­WINCH CI-JOINT. CERTAINS ÉTATS AMÉRICAINS NE PERMETTENT PAS D’EXCLURE OU DE LIMITER LES DOMMAGES INDIRECTS; IL EST DONC POSSIBLE QUE LA LIMITATION CI-DESSUS NE S’APPLIQUE PAS À VOTRE CAS. D. Condition de la garantie. Le Vendeur ne sera pas tenu de se conformer aux obligations de garantie fournies par les présentes si la cause du défaut, du mauvais fonctionnement ou de la panne du Superwinch est un dommage (ne résultant pas de composants défectueux ou qui fonc­tionnent mal) ou une utilisation déraisonnable par vous. Le terme Utilisation déraisonnable com­prend mais ne est pas limité au manquement à la maintenance, à l’installation et à l’utilisation raisonnables et nécessaires conformément aux consignes contenues dans le Mode d’emploi Superwinch, et à l’utilisation du Superwinch pour des charges supérieures à celle figurant dans le Mode d’emploi pour le modèle en question. La responsabilité du Vendeur sous la présente garantie ou pour toute perte du produit Superwinch ou dommage à celui-ci ne dépassera pas le coût de correction des défauts du produit Superwinch ou de remplacement de celui-ci, et lors de l’expiration de la période de garantie, toute telle responsabilité prendra fin. Les agents, distribu­teurs et employés du Vendeur ne sont pas autorisés à modifier la présente garantie ni à donner d’autres garanties complémentaires obligatoires pour le Vendeur. Toute déclaration supplémen­taire, qu’elle soit écrite ou orale, ne constituera donc pas une garantie et ne devra pas être consid­érée comme valable. REMEDES LÉGAUX DE L’ACHETEUR. Cette garantie limitée vous donne des droits légaux spécifiques et il est possible que vous ayez d’autres droits qui varient d’un état à l’autre aux Etats-Unis et d’un pays à l’autre. Vous avez également des droits de garantie implicite. En cas de problème avec le service ou la performance suivant la garantie limitée, il est possible que vous puissiez intenter une action en justice devant la Cour des Prudhommes (“small claims court”), devant le tribunal d’état ou devant le tribunal fédéral des Etats-Unis ou dans une autre juridiction appropriée en dehors des Etats-Unis. QUESTIONS. Toute question en ce qui concerne le respect des garanties énoncées dans les présentes doit être envoyée, par écrit, à : Superwinch, Inc., Winch Drive, Putnam, CT 08260 U.S.A. ou à Superwinch Limited, Abbey Rise, Whitchurch Road
GARANTIE LIMITÉE
OWNERS MANUAL
INSTALLATION OPERATION MAINTENANCE
SAFETY PRECAUTIONS REPAIR PARTS
C-SERIES
12 & 24 Volt DC Electric Winch
Models 03000, 03001, 03002,
03003, 03005, 03010
READ AND UNDERSTAND THIS MANUAL
BEFORE INSTALLATION AND OPERATION
OF YOUR SUPERWINCH PRODUCT.
89-10865 Rev - 2/20/03
Superwinch, Inc. Superwinch, Ltd. Winch Drive Abbey Rise, Whitchurch Road Putnam, CT 06260 Tavistock, Devon PL 19 9DR U.S.A. England Tel. (860) 928-7787 Tel. +44 (0) 1822 614101 Fax (860) 963-0811 Fax +44 (0) 1822 615204
Model 03000
Model 03001
Model 03003
Models
03002 03005 03010
2
The C1000 electric winch is for intermittent duty only. Motor cool-down time is required. Can be mounted horizontally or vertically. Winch can be utilized in a variety of lifting operations involving machinery, trucks, boats, farm implements, etc. Equipped with DC motor, permanently lubricated/sealed gear box, switch with harness assembly, handsaver, and pulley block.
For additional information, consult Specifications and Performance.
DESCRIPTION
UNPACKING
Electric Motor - 1.3 peak hp (0.9 kW) 12 Volt Permanent Magnet.
Gear Ratio . . . . . . . . . . . . . . . 159:1
Braking - A wrap spring brake will
support the load when power to the motor stops.
Remote Switch - 12 (3.66m) Hand held pendant switch assembly with interlocking reverse switch and trigger.
Working Load* . 1,000 lbs (454 kg)
Safety Factor . . . . . . . . . . . . . . 5:1
(*) Based on first layer performance.
SPECIFICATIONS
This equipment must be used as recommended by the manufacturer. Failure to follow these recommendations
could endanger your life and/or cause property damage.
Please unpack carefully and read the instructions before beginning. Inspect carefully for any damage that may have occurred during transit. Check for loose, missing or damaged parts.
3
Winch assembly with roller fairlead (no wire rope) 1 1 1 1
Winch assembly with roller fairlead (with wire rope) 1 1
Bolts, nuts, lockwashers 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea.
Flat washers 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea.
Cable ties 5 5 5 5 5 5
Owner’s Manual 1 1 1 1 1 1
Remote control switch 1 1 1 1
Without control switch 1 1
Circuit breaker assembly 1 1 1 1
Pulley block assembly 1
Handsaver 1 1 1 1 1 1
Internal solenoids 111
External solenoids 1
12 Volt Motor 1 1 1 1 1
24 Volt Motor 1
Quantity
Description 03000 03001 03002 03003 03005 03010
Load Speed Current Draw* (amps) lbs. kg ft/min m/min 12V 24V
0 0 19.5 5.9 30 15
1000 454 14.7 4.5 80 40
(*) Based on first layer performance.
PERFORMANCE
DIMENSIONS
15.1
(383)
3.1
(79)
1.24
(31.5
)
6.0
(152)
5.9
(150)
3.69
(93.7
7.1
(180)
7.2
(183)
MODELS 03002, 03005, 03010
4
MODEL 03000
6.0
(152)
15.1
(383)
7.1
(179)
3.69
(93.7)
5.9
(149)
1.25 (31.8)
7.1
(179)
NOTES:
1. All dimensions are in inches (millimeters).
2. Typical mount is to flat surface capable of handling the loads. Bolts to be Grade 5 or better.
5
MODEL 03001
MODEL 03003
6.0
(152)
13.6
(346)
1.25 (31.8)
3.69
(93.7)
7.1
(179)
5.9
(149)
6.0
(152)
13.6
(346)
5.9
(149)
7.1
(179)
1.25 (31.8)
3.69
(93.7)
6
Do not use for
lifting, support­ing, or transporting people, or over areas where people are present. Disconnect power before servicing.
1. READ AND SAVE ALL
INSTRUCTIONS.
2. DO NOT OVERLOAD. See
Performance information. Do not maintain power to the winch if the motor stalls. Overloads can damage the winch and create unsafe operating conditions.
3. LEARN TO USE WINCH. After
installing your winch, take the time to practice using it so that you are comfortable with it when the need arises. Periodically check the winch installation to assure that all bolts are tight.
4. NEVER ALLOW CHILDREN OR
UNTRAINED PERSONNEL TO OPERATE WINCH.
5. INSPECT ELECTRIC CABLE FIT-
TINGS FOR TIGHTNESS BEFORE EACH USE.
6. REPLACE DAMAGED OR BROKEN
PARTS IMMEDIATELY WITH MAN­UFACTURERS RECOMMENDED REPLACEMENT PARTS.
Never connect
winch to 110VAC power as fatal shock may occur.
7. USE CAUTION WHEN using
the winch. KEEP PEOPLE, PETS, AND PROPERTY CLEAR OF THE PATH OF THE LOAD. DO NOT USE WINCH TO LIFT OR MOVE PEOPLE.
8. DO NOT USE THE WINCH TO
SUPPORT AN UNATTENDED LOAD.
9. KEEP THE ELECTRIC CABLES FROM HEAT, OIL, AND SHARP EDGES. Periodically inspect for damage.
10. DO NOT OPERATE THE WINCH
WHEN TIRED OR UNDER THE INFLUENCE OF DRUGS, ALC0HOL, OR MEDICATION.
11. NEVER INSTALL WINCH IN SUCH
A WAY THAT THE WARNING AND INSTRUCTION LABELS ARE OBSCURED. Someone who has not read this manual may need to see them to understand the proper operation of the winch.
12. Always operate the winch with
an unobstructed view of the winching operation.
13. CHECK FOR CORRECT DIRECTION
OF ROTATION BEFORE USING WINCH. The winch must be properly wired to ensure correct direction of drum rotation.
14. REMOVE AND STORE THE
REMOTE PENDANT ASSEMBLY IN A SAFE PLACE when not in use to prevent unauthorized use.
15. ALWAYS UNPLUG THE
REMOTE PENDANT BEFORE WORKING IN OR AROUND THE ROLLER FAIRLEAD OR WINCH DRUM (THE DAN­GER ZONE) to prevent the winch from being turned on accidentally. Use handsaver when winding end of wire rope.
16. When lifting a load, slowly take
up the slack until it becomes taut. Stop, recheck all winching connections.
17. DO NOT MACHINE OR WELD
ANY PART OF THE WINCH. Such alterations may weaken the structural integrity of the winch, and void your warranty.
18. Never allow shock loads to be
applied to winch.
GENERAL SAFETY
INFORMATION
LOCATION
Mount the winch to a firm base. The structure the winch is attached to must be capable of withstanding a load greater than 1-1/2 times the winch’s rated line pull.
The winch can be mounted in a horizontal or vertical position. Do not mount the winch where there would be the possibility of it being submerged in water. The winch is weather resistant but not waterproof.
This winch MUST
be mounted with the pull in the underwind direc­tion. Improper mounting could dam­age your winch, cause the brake to not work and void your warranty.
Step (1)
Install structural support for winch. See "Dimensions" section for winch dimensions.
Step (2)
Mount the winch to the mount that you have designed.
Mounting bolts supplied are the correct length for use with a 1/4" (6.3mm) thick mounting plate.
Do not substi-
tute any bolt with strength weaker than grade 5.
When attaching wire to the motor terminals and solenoids (relays), hold the inner nut when tightening the outer nut. Do not allow the ter­minals to rotate. It may cause inter­nal wire breakage or part misalign­ment. Be especially careful in pre­venting the solenoid (relay) termi­nals from rotating. Any rotation can damage the solenoid (See Figure 1).
Step (3)
Disconnect the battery leads.
Batteries con-
tain gases which are flammable and explosive. Wear eye protection during installa­tion and remove all metal jewelry. Do not lean over battery while making connections.
Step (4) Model 03003
Select a convenient location for mounting the Solenoid Remote Control Assembly. The solenoid
INSTALLATION
Figure 1
7
REVERSAL SWITCH
(Switch may be in
Either Position)
OFF
REVERSAL SWITCH
(Rope-In position)
WIRE ROPE IN
WIRE ROPE OUT
REVERSAL SWITCH
(Rope-Out position)
Electrical Schematic
Green
Black
4
3
1
Trigger
Switch
Load
Line
White
NC
NC
Winch Motor
Green
Black
4
3
1
Trigger
Switch
Load
Line
White
NC
NC
Winch Motor
Green
Black
4
3
1
Trigger
Switch
Load
Line
White
NC
NC
Winch Motor
7
Figure 2
mounting plate must be electrically grounded to the battery. If it is not, the winch will not work. Preferably, the solenoids should be mounted vertically, with the solenoid end ter­minals pointing downwards.
Electrical Connection
Cut two lengths of wire, one red and one black, to reach from the winch to the solenoids. When rout­ing all wires, be sure to keep them away from all hot or moving parts. Crimp a 1/4" ring terminal on the end of each wire at the winch end. Attach one wire to each motor ter­minal (See figure 3). Crimp a 5/16" ring terminal at the solenoid ends of the wires and attach to the ter­minals on the solenoid assembly as shown in Figure 3.
Cut and strip two lengths of wire, one red and one black, to reach from the solenoids to the battery. On the battery end of the red wire, install a 3/16 ring terminal, and attach to the circuit breaker. The other end of the circuit breaker attaches to the harness. On the opposite end of this wire, connect a 5/16 ring terminal and attach to the solenoid assembly (See Figure 3).
Install 5/16 ring terminals to both
ends of the black wire. Connect one end to the solenoid assembly, and the other end to the battery nega­tive terminal (See Figure 3).
Connect the circuit breaker assem­bly bracket to the battery positive terminal.
Plug in the remote control, and with the directional lever in the Rope Out position, momentarily depress the trigger to check for proper rota­tion direction of the winch drum. If the winch runs in the wrong direc­tion, reverse the wires connected to the winch motor.
Step (4) Models 03000, 03001
These winches are supplied without controls. To design the control sys­tem for your application, you can purchase the needed materials to complete your system from Superwinch, or buy them locally.
You will need a switch or a solenoid control, a circuit breaker, hook up wire, and wire terminals.
Switch
Select a (3) position reversing switch with a switch action of momentary on”/“off”/“momentary on”. Momentary on means the switch automatically returns to OFF posi­tion when released. Minimum con­tact rating must be 50 amp DC carry.
Superwinch offers a (3) Position Heavy Duty Rotary Switch Part Number 1591. The Superwinch switch has an internal shunt that provides dynamic braking to further assist the winch's brake. (See Figure 4)
Solenoids
You will need (2) 12 Volt double pole, double through solenoids, with a continuous current rating of 80 amps on the normally open con­tacts and 60 amps on the normally closed contacts.
8
Figure 3
Superwinch offers an external sole­noid pack as shown with Model
03003. (Superwinch Part Number 1515A Remote Control). It comes with 12 foot pendant, 20 feet of 8 gauge wire, and instructions.
Circuit Breaker
We recommend using a 40 Amp Circuit Breaker between the battery positive terminal and the wire that goes to the switch or solenoid pack (See Figure 5). This can be pur­chased from Superwinch as Part Number 89-32341. The circuit break­er prevents overloads to the switch and to the winch motor.
Hookup Wire
If the total length of wire required is less than 20 feet, use 8 gauge wire. If the total length of wire required exceeds 20 feet, use 6 gauge wire.
Step (4) Models 03002, 03005, 03010
Route the (2) wires to the battery. To ensure against insulation abra­sion and/or cutting, apply several layers of electrical tape where wiring may come in contact with sharp metal parts. Attach the circuit breaker assembly to the end of the blue terminated wire. Wrap the cir­cuit breaker assembly with electrical tape to prevent accidental short circuits.
Note: If you choose to locate the winch at a greater distance than the wires provided will permit, it may be necessary to purchase a larg­er gauge wire to get the best per­formance from your winch. If the total length of additional wire to be added to the system exceeds 10 ft. (3m), use a larger wire gauge size.
Attach the circuit breaker directly to the battery positive terminal, and reattach the terminal to the battery.
Connect the remaining wire to the battery negative terminal, and con­nect the terminal to the battery. (See Figure 5)
Step (5)
Pull the trigger momentarily to check wire rope drum rotation and direction. If the drum rotates in the wrong direction, recheck your wiring.
The hand-held pendant switch acti­vates a solenoid that activates power to the winch motor. One solenoid is for power-in (lifting a load) motor direction and the other is for power-out (lowering a load) motor direction (See Figure 6).
9
Remote Switch Receptacle
Solenoid Assembly
Motor
Green
Black
Black
Blue Terminated
White
Circuit Breaker
Figure 5
+
Figure 4
10
PENDANT OPERATION
The switch trigger returns to the OFF position when released (See Figure 6, Ref. A). The slide button on the back of the switch deter­mines the direction of the drum rotation for lowering or lifting a load (See Figure 6, Ref. B). The slide is fitted with an interlock so that the motor cannot be reversed if the trigger is depressed. To change direction, release the trigger, move the slide button, and depress the trigger again.
The switch
assembly must be kept free of dirt and moisture to ensure safe operation.
To connect the pendant control, lift the dust cover on the plug recep­tacle (See Figure 7), and insert the plug end of the remote switch. The plug on the pendant control cord is keyed and will fit into the socket only one way.
Do not allow winch motor to over­heat. The winch is for intermittent use only. During long or heavy pulls
the motor will get hot. Allow to cool after 2 minutes of ON time.
MAINTENANCE AND REPAIR
Periodically check tightness of mounting bolts and electrical con­nections. Remove any dirt or corro­sion that may have accumulated on the electrical connections.
BRAKE OPERATION
Your winch has a wrap spring brake that stops and holds loads up to 1,000 lb. (454 kg). When the winch is powered out, as in releasing a load, the brake is engaged and the motor must overpower the brake resistance to rotate the drum. Therefore, it is normal for the winch to operate faster in one direction than the other. The brake is designed for the wire rope to be used in the underwind position only. Drum must turn counterclock­wise, looking from motor end, when winching in.
DO NOT
OVERWIND.
Powering against the brake will cause heat to build up in the drum and may transfer heat to the wire rope. DO NOT POWER OUT FOR MORE THAN 2 MINUTES.
The drum may get very hot.
WIRE ROPE
For safety reasons, it is important that you use a wire rope with a break strength of at least 5,600 lbs.
Recommended wire rope for this winch will have a 1/4" diameter with a 7 x 19 construction, and a minimum break strength of 7,000 lbs. or a 7/32" diameter with 7 x 19 construction, with a minimum break strength of 5,600 lbs.
OPERATION
Figure 6
POWER
OUT
POWER
IN
A
B
Figure 7
DUST COVER
REPLACING THE WIRE ROPE
Replace damaged wire rope with the manufacturer’s recommended replacement part or a factory approved equivalent identical in strength, quality, lay, and stranding. Pass the attaching end of wire rope through the fairlead and attach it to the drum. When inserting the wire rope into the drum, insert it into the correct end of the hole provided (See Figure 8). Tighten the set screw securely.
It is important that the wire rope be wound tightly onto the drum.
HANDLING THE WIRE ROPE
Use heavy
leather gloves when handling wire rope. Do not allow wire rope to slide through hands.
1. Never winch with less than 5
turns of wire rope around winch drum, since wire rope and fasten­er may not withstand the load.
ALWAYS USE HANDSAVER BAR WHEN GUIDING HOOK FOR THE LAST FEW FEET OF ROPE (See Figure 9)
Keep clear of
winch wire rope and hook when operating winch. Never put your finger through the­hook. Placing finger(s) in hook could result in injury.
2. Never hook wire rope back onto
itself. Hooking wire rope onto itself can damage rope. Use a nylon sling (See Figure 10). When using a sling, make sure that sling is properly seated in saddle of hook.
Avoid continu-
ous pulls from extreme angles. This will cause wire rope to pile up at one end of drum. This can jam wire rope in winch causing damage to rope or winch itself.
3. Do not use wire rope as a ground
for welding.
4. Never touch welding electrode to
wire rope.
5. Keep wire rope tight and even on
drum.
6. Replace wire rope when frayed.
TIPS FOR EXTENDING THE LIFE OF YOUR WINCH
1. Keep a tightly wound wire rope
drum. Do not allow the wire rope to become loosely wound. A loosely-wound drum allows a wire rope under load to work its way down into the layers of wire rope on the drum. When this happens, the wire rope may become wedged within the body of the windings, damaging the
11
Figure 10
Right
Wrong
Figure 8
Figure 9
wire rope. To prevent this prob­lem, keep the wire rope tightly and evenly wound on the drum at all times. A good practice is to rewind the wire rope under ten­sion after each use. One way to do this is to attach the hook to a small load and winch that load to rewind rope.
2. To maximize winch and wire rope life, use pulley block to double line heavier loads.
3. PREVENT KINKS BEFORE THEY OCCUR. (See Figure 11.)
a. This is the start of a kink. At this
time, the wire rope should be straightened.
b. The wire rope was pulled and the
loop has tightened to a kink. The wire rope is now permanently dam­aged and must be replaced.
c. Kinking causes the wire strands
under the greatest tension to break and thus reduces the load capacity of the wire rope. The wire rope must be replaced.
LUBRICATION
The winch is permanently lubri­cated. There may be grease leakage out of winch, especially during first few operations. This is normal and it is not necessary to grease or oil any internal part of winch at any time.
Periodically lightly lubricate wire rope with penetration oil and wipe off excess.
Figure 11
a
b
c
12
TROUBLESHOOTING
CHART
Motor will not operate or 1. Damaged or stuck CAUTION Be prepared to runs in one direction only solenoid disconnect power when
performing this test. If a solenoid sticks once, it is likely to stick again and must be replaced immediately
.
1. Tap solenoid to free stuck contacts. Check by applying voltage to the small solenoid terminal. Be sure solenoid is grounded back to source. A solenoid that is not stuck will make an audible click” when first energized.
2. Switch inoperative 2. Replace switch.
3. Broken wires or bad connection 3. Check for poor connections.
CAUTION Always use 2 wrenches (See Figure 1).
4. Damaged motor 4 Replace or repair motor.
5. Solenoids not grounded 5. Check the ground path between battery negative and solenoid base.
Winch will not shut off Solenoid stuck “ON If a solenoid sticks on, reverse
direction and hold trigger switch until the power lead can be dis­connected. A safety disconnect switch is available as an accessory.
Motor runs extremely hot 1. Long period of operation 1. Allow to cool.
2. Damaged motor 2. Replace or repair motor.
3. Damaged brake 3. Replace or repair brake.
Motor runs but with insufficient 1. Weak battery 1. Recharge or replace battery. power or line speed Check charging system.
2. Battery to winch wire
extended with same size wire 2. Use larger diameter wire.
3. Poor battery connection 3. Check battery terminals for corrosion. Clean as required.
4. Poor ground 4. Check and clean connections.
5. Damaged brake 5. Repair or replace brake.
Winch runs backward 1. Motor wires reversed 1. Recheck wiring.
2. Solenoids wired incorrectly 2. Recheck wiring.
Will not hold load 1. Excessive load 1. Reduce load or double line.
2. Worn or damaged brake 2. Repair or replace brake.
Symptom Possible Cause(s) Corrective Action
13
14
REPLACEMENT
PARTS
1
2
3
4
5
6
7
8
9
29
10
11
12
13
11
14
15
16
17
19
37
34
37
25
26
30
27
28
29
26
23
24
21
22
20
34
33
36
32
33
31
37&38
2
18
Safety
65
15
1 Base 89-52021 1 2 Groove pin 89-23303-01 2 3 Cable guard 89-32268 1 4 Main bearing 89-22268 1 5 Drum 89-40152 1 6 M6 x 1 x 8mm Set PT screw 90-23164-12 2 7 Brake spring 89-22342 1 8 Brake adapter 89-22287 1 9 Drum bearing 89-22269 1 10 Drum support 89-40092 1 11 Thrust washer 90-12574 2 12 Drive plate 89-32263 1 13 Rotating ring gear 89-32265 1 14 Planetary carrier assembly 89-22141 1 15 Wear washer 89-22271 1 16 Sun gear 89-32253 1 17 Stationary Ring Gear 89-32266 1 18 Housing Assembly 89-40157 1 19 12V Motor (03000, 03001, 03002, 03003, 03005) 90-33256 1
24V Motor (03010) 89-32386 1 20 Cable Tension Plate 89-32295 1 21 Screw, FCHSS M6 x 1 x 16 87-22291-02 4 22 Roller Fairlead Shaft (Includes 22-27) 1 23 Roller Fairlead Shaft (Long) 89-22334-02 2 24 Roller Fairlead Frame 89-40113 1 25 Roller Fairlead Shaft (Short) 89-22334-01 2 26 3/8 Retaining Ring 90-23029-08 4 27 5/8 x 2.352 Roller 90-12568-04 2 28 5/8 x 4.735 Roller 90-12568-06 2 29 M6 x 1 x 13mm BHDCS Screw 89-22290-01 2 30 M6 x 1 x 16mm BHDCS Screw 89-22290-02 5 31 Motor Cover Assembly (03000) 89-40131 1
(includes logo, 34 & 37)
32 Motor Cover Assembly (03002, 03005, 03010) 89-40131-03 1
(Includes logo, 34 & 37) 33 M4 x 0.7 x 6mm (03000, 03002, 03005, 03010) 89-22292-01 4 34 Filler Block (03000, 03002, 03005, 03010) 89-12032 1
36 SKT Half Connector (03002, 03005, 03010) 90-22115 1 37 8-32 Pan Head Screw (03000) 90-23032-03 1
8-32 Pan Head Screw (03002, 03005, 03010) 90-23032-03 3 38 8-32 Hex Flange Nut (03002, 03005, 03010) 90-23149-06 2 NS Handsaver Bar 89-32300 1 NS 1/4 x 25 Wire Rope Assembly (03005) 1577B 1 NS 1/4 x 50 Wire Rope Assembly (03010) 1577A 1 NS Pulley Block with Hook (03005) 2207 1 NS Mounting Hardware Package 90-22877 1 NS Terminal Package (03003) 90-22885 1 NS 12V Circuit Breaker Assembly (03002, 03003, 03005)87-22873-11 1 NS 24V Circuit Breaker Assembly (03010) 90-22873-01 1
(NS) Not Shown
Reference Number Description Part Number Qty
REPLACEMENT
PARTS LIST
REPLACEMENT
PARTS
55
56
54
42
51
50
49
48
47
54
46
67
36
64
53
46
16
37
36
59
60
38
50 51
53
57
54
46
61
62
46
54
63
58
REPLACEMENT
PARTS LIST
46 12V Solenoid (03002, 03003, 03005) 90-20329 2
24V Solenoid (03010) 90-20331 2
47 6 GA x 5 Leadwire Assembly (Pos) (03002, 03010) 90-23292-20 1
6 GA x 20 Leadwire Assembly (Pos) (03005) 89-23292-27 1
48 6 GA x 5 Leadwire Assembly (Neg) (03002, 03010) 90-20187-06 1
6 GA x 10 Leadwire Assembly (Neg) (03005) 89-23292-26 1 49 Ground Strap (03002, 03005, 03010) 89-22356 1 50 5/16 Lockwasher (03002, 03003, 03005, 03010) 92-23057-03 1 51 5/16-18 Hex Nut (03002, 03003, 03005, 03010) 92-23034-04 1 52 6 GA x 3 1/2 Leadwire Assembly 90-23292-06 1
(03002, 03005, 03010) 53 Buss Bar 2 Assembly (03002, 03003, 03005, 03010) 92-10200 1 54 Buss Bar 1 (03002, 03005, 03010) 92-20126 2 55 8 GA x 9 3/8 Leadwire Assembly (Red) (03005) 89-23292-21 1
8 GA 9 3/8 Leadwire Assembly (03002, 03010) 90-20187-08 1
56 8 GA x 6 Leadwire Assembly (Black) (03005) 89-23306-02 1
6 GA x 6 Leadwire Assembly (03002, 03010) 89-23292-19 1 57 Buss Bar 3 (03003) 92-20128 1 58 6 GA x 2 3/4Leadwire Assembly (03003) 90-20187-07 1 59 8-32 x 1/4 HW Taptite Screw (03003) 90-22247 1 60 8-32 x 1/4 HW Taptite Screw (03003) 90-23039-03 4 61 10-32 Flange Hex Nut (03003) 90-23149-01 4 62 Solenoid Pack Back Plate (03003) 90-32070 1 63 12V Remote Solenoid Pack (03003) 90-32139
(Includes 35, 36, 37, 46, 49, 52, 54, 60, 65, 66, 67, 68 64 Remote Control Assembly 90-22117 1
(03002, 03003, 03005, 03010) 65 Safety Label, 3/4 icon, 3 x 2 89-20330 1
Reference Number Description Part Number Qty
17
Loading...
+ 42 hidden pages