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WINCH MAINTENANCE
Adhering to the following maintenance schedule will keep your winch in top condition and performing as it should with a minimum of
repair.
A.
WEEKLY
1.
Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and repair.
2.
Check the pressure relief plug in top of the gear housing. Be sure that it is in good operating condition so that hot oil ga sses
may escape.
3.
Lubricate rope with light oil.
B.
MONTHLY
1.
Lubricate the various grease fittings located in the rope drum, end bearing, clutch housing or clutch operating linkage. Any
good grade of moly-disulfide containing grease is acceptable.
2.
Check the action of the sliding clutch, making sure it is fully engaging and disengaging with the rope drum. Remove the plas tic
plug in top of the housing and observe if the clutch is fully engaging. If clutch is not fully engaging, inspect clutch shifter assem-
bly parts, check for damage or excessive wear and replace as necessary. Observe the jaws on both the clutch and rope drum,
checking for rounding of the driving faces. If rounding has occurred they should be replaced immediately.
3.
Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are loose. Make sure to use
only grade 5 bolts or better.
4.
Inspect the rope. If the rope has become frayed with broken strands, replace immediately.
C.
ANNUALLY
1.
Drain the oil from the winch annually or more often if winch is used frequently.
2.
Fill the winch to the oil level plug with clean kerosene. Run the winch a few minutes with no load in the reel in direction. Drain
the kerosene from the winch.
3.
Refill the winch to the oil level plug with all purpose E.P. 140 gear oil.
4.
Inspect frame and surrounding structure for cracks or deformation.
5.
Gear wear can be estimated by rocking the drum back and forth and if necessary drain oil and remove cover for closer inspec-
tion.
ELECTRICAL CONNECTIONS
For normal self-recovery work, your existing electrical system is adequate. Your battery must be kept in good condition. A
fully charged battery and proper connections are essential. Run the vehicle engine during winching operation to keep bat-
tery charged. Connect red cable from stud on plastic solenoid cover on winch to emergency stop solenoid. Important:
Hold inner nut with end wrench while tightening outer nut. Install emergency stop switch and solenoid per kit # 282067
(12V) or 282068 (24V) as applicable.
Connect black cable from motor ground stud to negative battery termi nal. A good electrical ground is required for proper
performance. The remote control switch is waterproof and has push button stations on either side. It is designed this
way to prevent quick winch reversals, which lead to solenoid failure. Make sure the winch motor has stopped fully before
reversing. When first setting up your winch, follow the directions for inserting the proper "IN" or "OUT" label in the thumb
button. The switch is also color coded to aid you in determining the direction your winch will run.
ADJUSTMENT OF RATED LOAD LIMITER
1. Make some test pulls with winch (using a load cell or spring scale) to determine if switch is at desired rated load set
ting.
Applicable setting is 100% to 125% of rated load.
2. If load is not within above range, remove tamper-proof compound in threaded hole (on top of set screws #4). Remove
top set screw.
3. Loosen bottom set screw approximately 2 turns counter clockwise.
4. To reduce line pull, thread switch #1 "IN" by turning clockwise. To increase line pull, the switch "OUT".
5. After desired setting is reached, tighten bottom set screw securely.
6. Re-install top set screw and tighten securely. Fill threaded hole with a potting-type compound which must be removed
before any future adjustment is made.
END OF SERVICE MEASURES
When winch reaches the end of its serviceable life, dispose of per local environmental regulations.
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