Safety and Warnings
Each winch is equipped with a permanent magnet motor and is designed for intermittent duty general use. The winch is not designed to be used in industrial or hoisting applications and the unit is not suitable or safe for such use.
A free spool clutch is operated by a pull and turn knob which disengages the gearbox to allow the wire rope to be pulled out without using electric power. A tension plate reduces backlash and snarling when pulling out the wire rope.
- Never lift people or hoist loads over people. Do not lift items vertically. The winch was designed for horizontal use only.
- Do not overload. For loads over 2250lbs, we recommend the use of the optional pulley block to double line the wire rope. (Figure 1)
- Do not attempt prolonged pulls at heavy loads. The electric winch is designed for intermittent use only, and should not be used in a constant duty application. The duration of the pulling job should be kept as short as possible. If the winch motor becomes very hot to the touch, stop the winch and let it cool down for several minutes. Never pull for more than one minute at or near the rated load.
- Never winch with less than 5 turns of wire rope around the winch drum since the wire rope end fastener may not withstand full load.
- Avoid continuous pulls from extreme angles as this will cause the wire rope to pile up on one end of the drum (Figure 2). This can jam the wire rope in the winch, causing damage to the rope or the winch.
- Be sure the input voltage between the terminals of the motor is always 12v DC in order to reach the max rated line pull during operation. Note that it only can reach the max rated line pull by the first layer of cable around the drum when pulling the loads.
- Never hook the wire rope back onto itself because you could damage the wire rope. Use a nylon sling. (Figure 3)
- Be sure the winch is mounted on the vehicle or solid object before operating.
- When moving a load, slowly take up the wire rope slack until it becomes taut. Stop, recheck all winching connections. Be sure the hook is properly seated. If a nylon sling is used, check the attachment to the load.
- It is a good idea to lay a heavy blanket or jacket over the wire rope near the hook end when pulling heavy loads (Figure 3 ). If a wire rope failure should occur, the cloth will act as a damper and help prevent the rope from whipping. The wire still may whip, so always keep clear when winching.
- Do not move your vehicle to assist the winch in pulling the load. The combination of the winch and vehicle pulling together could overload the wire rope and the winch.
- Never work on or around the winch drum when the winch is under load. (Keep at least 3 meters away at all times when the rope is under load).
- Do not cross over or under the wire rope when the winch is under load. (Keep at least 3 meters away at all times when the rope is under load).
- When using your winch to move a load, place the vehicle transmission in neutral, set vehicle brake, and chock all wheels. The vehicle engine should be running during winch operation. If considerable winching is performed with the engine off, the battery may be too weak to restart the engine.
- Never release the free spool clutch when there is a load on the winch.
- After winching is completed, release the load. Do not allow the cable to stay taut.
- Always stand clear of wire rope, hook and winch, and do not approach the assembly until the rope is no longer taut.
- Inspect the wire rope and equipment frequently. A frayed wire rope with broken strands should be replaced immediately. Only use factory approved switches, remote controls and accessories. Use heavy leather gloves when handling wire rope. Do not let wire rope slide through your hands.
- Keep clear of the winch, taut wire rope and hook when operating the winch. Never put your finger through the hook. Always use the hand saver bar when guiding the wire rope in or out.
- After operating the winch, re-spool the cable around the drum tightly.
- Do not operate winch when under the influence of drugs, alcohol or medication. Always stay alert during the operation.
- Do not machine or weld any part of the winch. Such alterations may weaken the structural integrity of the winch and could void your warranty.
- Regularly maintain the winch and check for any wear or damage before use.
Product Overview
|
Item # |
Part# |
Qty |
Description |
|
1 |
200100 |
1 |
Motor |
|
2 |
200200 |
1 |
Stationary Gear Housing Assembly |
|
3 |
200300 |
1 |
T-Series Carrier Assembly |
|
4 |
200400 |
1 |
T-Series Rotator Gear |
|
5 |
200500 |
1 |
Drum Support Plate |
|
6 |
200600 |
4 |
Pan Head Screw M4X12 |
|
7 |
200700 |
1 |
Drum Support Bushing |
|
8 |
200800 |
1 |
Clutch Assembly |
|
9 |
200900 |
1 |
Spring |
|
10 |
200001 |
1 |
Drum Assembly |
|
11 |
200002 |
1 |
Screw M5X5 |
|
12 |
200003 |
1 |
T-Series Bushing |
|
13 |
200004 |
1 |
Thick Flat Washer |
|
14 |
200005 |
2 |
Hex Flange Nut M5 |
|
15 |
200006 |
1 |
T-Series Baseplate Assembly |
|
16 |
200007 |
1 |
Tension Plate |
|
17 |
200008 |
1 |
T-Series F/W Knob Assembly |
|
18 |
200009 |
1 |
Elastic Pin 2.5x14 |
|
19 |
200010 |
2 |
Hex Skt FH Screw M6x16 |
|
20 |
200011 |
2 |
Screw |
|
21 |
200012 |
2 |
Screw M8x30 |
|
22 |
200013 |
2 |
Washer-Flat 08 |
|
23 |
200014 |
2 |
Lock Washer 08 |
|
24 |
200015 |
2 |
Nut M8 |
|
25 |
200016 |
1 |
Red strap |
|
26 |
200017 |
1 |
Switch Assembly |
|
27 |
200018 |
1 |
Cable Assembly |
|
28 |
200019 |
1 |
Tie Bar (2000lbs not need it) |
|
29 |
200021 |
1 |
Control Box |
|
30 |
200022 |
2 |
Relay |
|
31 |
200023 |
1 |
Wire |
|
32 |
200024 |
1 |
Wireless Switch |
When ordering parts from this list, make sure to indicate that the part number was from the Winch Parts List.
Installation
Correct installation of your winch is required for safe and proper operation.
1. Mount the winch on the vehicle or other object using M8 x 30 screws, lock washers, and flat washers. Ensure that the mounting point is extremely secure and is connected to the vehicle's chassis adequately.
WARNING: This winch must be mounted with the wire rope in the underwind direction. Improper mounting could damage your winch and void your warranty.
2. Route the two electrical cables from the switch to the motor and battery respectively. Connect the red line to the positive (+) terminal and the green (or black) line to the negative (-) terminal of the 12V battery. Connect the cables to the terminal on the motor of the electric winch (Figure 4).
3. Check the direction of the drum rotation. Pull and turn the clutch knob to the "Off" position (so the drum can rotate freely). Pull out the cable from the drum then engage the clutch by turning the knob to the "In" position. Push the "cable in" button on the handheld remote, if the cable is re-spooling then it is connected correctly. If the motor is turning in the wrong direction change the positive and negative electrical cables so that they are connected to the opposite terminals. Check that the winch has been installed in the correct orientation. Repeat the above-mentioned steps to ensure the motor is now running in the correct direction.
Operation
1. Pull and turn the clutch knob to the "Off" position, so the drum can be turned freely by hand.
2. Grab the cable assembly hook and pull the cable to the desired length with the handsaver bar. Attach the cable assembly to the item being pulled.
Warning: Check that there are at least five turns of wire rope left on the drum before winching.
Warning: Never hook the wire rope back onto itself because you could damage the wire rope. Use a nylon sling. (Figure 3)
3. Engage the clutch by turning the clutch knob to the "In" position.
Warning: The clutch must be fully engaged before winching. NEVER engage the clutch knob while the drum is turning. The clutch knob has been adjusted and permanently locked in place with a thread locking compound at the factory. Do not attempt to re-adjust the knob.
4. Push and hold the "Cable In" button on the handheld remote and the cable will re-spool.
Push and hold the "Cable Out" button to reverse directions. Wait until the motor stops before reversing directions.
5. Respool the cable after winching has been completed.
Maintenance
1. Periodically check the tightness of the mounting bolts and electrical connections. Remove all the dirt or corrosion that may have accumulated on the electrical connections.
2. Do not attempt to disassemble the gearbox. Disassembly will void warranty. Repairs should be done by Certa.
3. The gearbox has been lubricated using high-temperature lithium grease at the factory. No internal lubrication is required.
Replacing the Wire Rope
1. Engage the clutch by turning the clutch knob to the "In" position.
2. When inserting the wire rope into the drum, insert it into the correct end of the hole provided. (Figure 5). Tighten the set screw securely.
3. Operate the winch and re-spool the wire rope around the drum.
CAUTION: Always replace damaged wire rope with manufacturers identical replacement part.
Specifications
| Performance Specifications Single line rated pull | 3000Lbs( 1361 kgs) |
|
Gear reduction ratio |
153:1 |
|
Motor |
Permanent magnet DC 12V motor with 1 hp output |
|
Overall dimensions |
7.3"(L)x4.1"(W)x4.1"(H) 300(L)x105(W)x105(H)mm |
|
Drum size |
φ1.24(D)x2.88"(L) φ31.5(D)x73(L)mm |
|
Cable length |
3O.lft(L) ofφ11/51" Cable 9.2m(L) ofφ5.5 mm Cable |
|
Weight |
14.3Lbs 6.5 Kgs |
Line speed and motor current (first layer)
|
Line Pull |
Lbs |
0 |
1000 |
2000 |
3000 |
|
Kgs |
0 |
454 |
906 |
1361 |
|
|
Line speed |
FPM |
10.5 |
7.5 |
4.2 |
2.3 |
|
MPM |
3.2 |
2.3 |
1.3 |
0.7 |
|
|
Motor current |
Amps |
10 |
40 |
90 |
145 |
Line pull and cable capacity
|
Layer of cable |
1 |
2 |
3 |
4 |
5 |
|
|
Rated line pull per layer |
Lbs |
3000 |
2250 |
1890 |
1590 |
1370 |
|
Kgs |
1361 |
1022 |
859 |
722 |
622 |
|
|
Cable capacity per layer |
Ft. |
4.9 |
11.5 |
19.3 |
28.5 |
30.1 |
|
M |
1.5 |
3.5 |
5.9 |
8.7 |
9.2 |
|
Circuit Diagram
Troubleshooting
| SYMPTOM | POSSIBLE CAUSE | SUGGESTED ACTION |
| The motor will not operate or runs in one direction only | - Switch inoperative -Broken wires or bad connection -Defective motor |
- Replace switch |
| Motor runs but the drum does not turn | - Clutch not engaged | - Engage clutch |
| Motor runs but with insufficient power or line speed |
- Weak battery - Defective motor |
- Recharge or replace the battery. - Check battery terminals for corrosion. Clean as required - Check and clean connections - Repair or replace the motor |
| Motor overheating | - Winch running time too long -Defective motor |
- Allow winch to cool down periodically - Repair or replace the motor |