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4WD ACCESSORIES
4WD winchINSTRUCTION MANUAL
YEAR WARRANTY
3AFTER SALES [email protected] 883 104
MODEL: 17-6068 PRODUCT CODE: 6068 09/2017
AUS
W2CONTENTS• 5443kg/12000LB Winch• Control Box C.W Attached Cables• Fairlead Roller• Attachment Kit for Fairlead Roller • Clevis Hook• Hand Control (Battery Included)• 1 Spare Alkaline 23A 12V Battery for
Hand Control • Cable to Connect Hand Control to Winch• Warranty Certi�cate • Instruction Manual
Version 3 May 2017
2
Contents
Page
WARRANTY DETAILS ...............................................................................................................................................................3
REPAIR AND REFURBISHED GOODS OR PARTS NOTICE .............................................................................................3
WELCOME ...................................................................................................................................................................................4
SAFETY PRECAUTIONS ..........................................................................................................................................................5
WINCH OPERATION WARNINGS .........................................................................................................................................6
REMOTE HAND CONTROL OPERATIONS .........................................................................................................................7
12V DC 4WD WINCH PARTS LIST ........................................................................................................................................8
12V DC 4WD WINCH PARTS LIST DIAGRAM ...................................................................................................................9
12V DC 4WD WINCH KIT ..................................................................................................................................................... 10
INSTALLATION ........................................................................................................................................................................ 11
ELECTRICAL CONNECTION ................................................................................................................................................ 12
OPERATION ............................................................................................................................................................................ 13
5443KGS/12000LBS LINE PULL AND CABLE CAPACITY TABLE ............................................................................. 14
WINCHING PRINCIPLES ....................................................................................................................................................... 14
SPECIFICATIONS .................................................................................................................................................................... 14
BATTERY REPLACEMENT .................................................................................................................................................... 15
RECEIVER COMPONENT REPLACEMENT ....................................................................................................................... 15
MAINTENANCE ...................................................................................................................................................................... 16
DISPOSAL ................................................................................................................................................................................ 16
FAQ ............................................................................................................................................................................................ 16
AFTER SALES SUPPORT
AUS Hotline Costs: Landline calls are free. Mobile costs are extra & aredependent on carrier charges – please check charges with your mobile carrier.
MODEL: 17-6068 PRODUCT CODE: 6068 09/2017
1300 883 104AUS [email protected], www.4x4tough.com.au YEAR WARRANTY
3
Repair and Refurbished Goods or Parts NoticeUnfortunately, from time to time, faulty products are manufactured which need to be returned to the Supplier for repair.Please be aware that if your product is capable of retaining user-generated data (such as �les stored on a computer hard drive, telephone numbers stored on a mobile telephone, songs stored on a portable media player, games saved on a games console or �les stored on a USB memory stick) during the process of repair, some or all of your stored data may be lost.We recommend you save this data elsewhere prior to sending the product for repair.You should also be aware that rather than repairing goods, we may replace them with refurbished goods of the same type or use refurbished parts in the repair process.Please be assured though, refurbished parts or replacements are only used where they meet ALDI’s stringent quality speci�cations.If at any time you feel your repair is being handled unsatisfactorily, you may escalate your complaint. Please telephone us on SUPPLIER TELEPHONE or write to us at:Motozone Auto AccessoriesPO Box 5213, Mordialloc Vic 3195Telephone: 1300 883 104Email: [email protected]: www.4x4tough.com.au
12V DC 4WD Electric Winch
Warranty DetailsREGISTER YOUR PURCHASE AT www.aldi.com.au/en/about-aldi/product-registration/ TO KEEP UP-TO-DATE WITH IMPORTANT PRODUCT INFORMATION
The product is guaranteed to be free from defects in workmanship and parts for a period of 36 months from the date of purchase. Defects that occur within this warranty period, under normal use and care, will be repaired, replaced or refunded at our discretion. The bene�ts conferred by this warranty are in addition to all rights and remedies in respect of the product that the consumer has under the Competition and Consumer Act 2010 and similar state and territory laws.Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
Remote Control Battery Replacement NoticeOccasionally, during shipment the battery inside the remote control may experience some power loss. For this reason, a replacement battery has been provided inside the re-sealable plastic bag. If, upon initial use of the remote control power loss is experienced, please replace the battery with the spare battery provided. Refer to Page 15. of the User Guide for detailed battery replacement instructions.
AFTER SALES SUPPORT
AUS Hotline Costs: Landline calls are free. Mobile costs are extra & aredependent on carrier charges – please check charges with your mobile carrier.
MODEL: 17-6068 PRODUCT CODE: 6068 09/2017
1300 883 104AUS [email protected], www.4x4tough.com.au YEAR WARRANTY
3
Repair and Refurbished Goods or Parts NoticeUnfortunately, from time to time, faulty products are manufactured which need to be returned to the Supplier for repair.Please be aware that if your product is capable of retaining user-generated data (such as �les stored on a computer hard drive, telephone numbers stored on a mobile telephone, songs stored on a portable media player, games saved on a games console or �les stored on a USB memory stick) during the process of repair, some or all of your stored data may be lost.We recommend you save this data elsewhere prior to sending the product for repair.You should also be aware that rather than repairing goods, we may replace them with refurbished goods of the same type or use refurbished parts in the repair process.Please be assured though, refurbished parts or replacements are only used where they meet ALDI’s stringent quality speci�cations.If at any time you feel your repair is being handled unsatisfactorily, you may escalate your complaint. Please telephone us on SUPPLIER TELEPHONE or write to us at:Motozone Auto AccessoriesPO Box 5213, Mordialloc Vic 3195Telephone: 1300 883 104Email: [email protected]: www.4x4tough.com.au
12V DC 4WD Electric Winch
Warranty DetailsREGISTER YOUR PURCHASE AT www.aldi.com.au/en/about-aldi/product-registration/ TO KEEP UP-TO-DATE WITH IMPORTANT PRODUCT INFORMATION
The product is guaranteed to be free from defects in workmanship and parts for a period of 36 months from the date of purchase. Defects that occur within this warranty period, under normal use and care, will be repaired, replaced or refunded at our discretion. The bene�ts conferred by this warranty are in addition to all rights and remedies in respect of the product that the consumer has under the Competition and Consumer Act 2010 and similar state and territory laws.Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
Remote Control Battery Replacement NoticeOccasionally, during shipment the battery inside the remote control may experience some power loss. For this reason, a replacement battery has been provided inside the re-sealable plastic bag. If, upon initial use of the remote control power loss is experienced, please replace the battery with the spare battery provided. Refer to Page 15. of the User Guide for detailed battery replacement instructions.
4
WELCOME
Satis�ed customers have repeatedly attested to the positive outcome of a simple phone call in resolving misunderstandings and gaining positive insights
into product usage.
This product is manufactured to the highest standards of safety and performance and is backed by a 3 year warranty.
Please read instructions carefully before use.
Unless directions are followed physical injury or property damage may result.
Save these instructions for future reference.
In the event you require assistance with your purchase please contact one of our experienced customer service team on 1300 883 104,
before considering a return of product to ALDI.
Congratulations on choosing to buy a 4X4 TOUGH® product.
5
Please read all instructions carefully before use. Unless directions are followed physical injury or property damage may result. Save these instructions for future reference.
This product complies with AS1418.2.
Safety PrecautionsRead the following carefully before attempting to operate your winch and keep the instructions for future reference.
This product should be installed by a suitably quali�ed technician.
1. Dress Properly:• Don’t wear loose clothing or jewellery which could get caught in moving parts.• Always wear leather rigging gloves supplied in this kit when handling winch cable. DO NOT handle cable with bare hands as
broken wires can cause injuries.• Non-slip footwear is recommended.• Protective hair covering to contain long hair.
2. Keep a Safe Distance:• Ensure that all persons stand well clear of winch cable and load during winch operation. 1.5 times the cable length is
recommended. If a cable pulls loose or breaks under load it can lash back and cause serious personal injury or death.• Draping a damper (sold separately) or similar object over the extended winch cable is essential as it will dampen any cable
backlash, in the event of the cable breaking or becoming unsecured under load.• Don’t step over the cable.• All onlookers should be kept away from the work area.• Keep proper footing and balance at all times.
3. Don’t Abuse the Cable:• Never carry the winch by the cable or yank it to disconnect it from the receptacle.• Keep cable away from heat, oil and sharp edges.
4. Don’t Overwork the Winch:• If the motor becomes hot to touch, stop and let it cool for a few minutes.• Don’t maintain power to the winch if the motor stalls.• Don’t exceed maximum line pull ratings shown in the table. (Refer to ‘Line Pull and Cable Capacity Table’ - Page 13) Shock loads
must not exceed these ratings.
5. Avoid Unintentional Starting:• To avoid accidental engagement of the winch, ensure your battery isolation switch is in the o� position.• Refer to Installation section on Page 10 this manual.
6. Check Damaged Parts:• Before using, check your winch carefully. Any part that is damaged should be properly repaired or
replaced by an authorised service centre.
7. Repairs to the Winch:• This product should only be repaired by a suitably quali�ed technician using genuine parts.
8. Respool the Cable:• Leather gloves must be worn while respooling. To respool correctly, it is necessary to keep a slight load on the cable. Hold
the cable with one hand and the remote control switch with the other. Start as far back and in the centre as you can. Walk up keeping load on the cable as the winch is powered in.
• Cautiously spool in the cable under power, keeping hands clear of the fairlead roller to ensure the user is not exposed to the possibility of having their hand caught.
Warning: The use of any other accessory or attachment other than those recommended in the Instruction manual may present a risk of personal injury and equipment damage.
6
Winch Operation WarningsRead the following carefully before attempting to operate your winch and keep the instructions for future reference.
1. This winch is �tted with an in-built thermal overload to prevent damage. If the winch stops during operation turn the winch o� and allow it to cool before continuing.
2. The uneven spooling of cable, can be a problem, if the cable should build up too high and cause friction with the outside of the cable casing. If this should happen, reverse the cable and respool in a more even manner �nish. On completion of winching, unspool and rewind for a neat lay on the drum; refer point 14 below.
3. Store the remote control switch inside your vehicle where it will not become damaged. Inspect it before you plug it in.
4. When ready to begin spooling in, plug in remote control switch with clutch disengaged. DO NOT engage clutch with motor running.
5. Never connect the hook back to the cable. This causes cable damage. Always use a sling or chain of suitable strength.
6. Observe your winch while standing at a safe distance. Stop the winching process every metre or so to assure the cable is not pulling up in one corner. Jamming the cable can break your winch.
7. The use of a snatch block may aid recovery operations by providing a doubling of the winch capacity and a halving of the winching speed, or further it could provide an opportunity to achieve a direct line pull to the centre of the rollers, facilitating a more even recovery of the cable on the drum. When double loading during stationary winching, the winch hook should be attached to a rated recovery point.
8. Ensure rated “D” or bow shackles are used in conjunction with an approved tree trunk protector to provide a safe anchor point. Always use shackles that comply with AS/2741 – 2002. A 4.7 Tonne shackle is required.
9. When extending winch cable, ensure that at least �ve wraps of cable remain on drum at all times. Failure to do this could result in the cable parting from the drum under load. Serious personal injury or property damage may result.
10. All winches are provided with a Red Marking on the cable to identify that 5 cable wraps remain on the winch drum. When this mark appears at the rollers, no recovery should be attempted beyond this marking.
11. Since the greatest pulling power is achieved on the inner most layer of your winch, it is desirable to pull o� as much cable as practical, not with standing the need to maintain a minimum of 5 wraps of cable on the drum. If this is not practical use a snatch block and double line arrangement.
12. Draping a damper (sold separately) or similar object over the extended winch cable is essential as it will improve safety, by dampening any backlash should a failure occur.
13. Neat, tight spooling avoids cable binding, which is caused when a load is applied and the cable is pinched between other cable spools. If this happens, alternatively power the winch in and out. DO NOT attempt to work a bound cable under load - free by hand.
14. Apply blocks to wheels of winching vehicle when vehicles are on an incline.
15. Battery:
• Be sure that the vehicle’s battery is in good condition. Avoid contact with battery acid or other contaminants.
• Always wear eye protection when working around a battery.
• Have the engine running when using the winch to avoid �attening the battery.
16. Winch Cable:
• DO NOT recover winch cable beyond a comfortable snug �t on the drum. Over recovery may put excessive pressure on the clutch making it impossible to disengage the clutch lever.
• Be sure that the cable is in good condition and is attached properly.
• DO NOT use the winch if cable is frayed.
• DO NOT move the vehicle to pull a load.
• DO NOT replace the cable with a cable of lesser strength.
7
• The life of the cable is directly related to the use and care it receives. Following its �rst and subsequent uses, a cable must be wound on to the drum under a load of at least 500lbs (230kg) or the outer wraps will draw into the inner wraps and severely damage the cable during winching. The �rst winch use should be a familiarisation run while in a relaxed, non-recovery situation. Spool out the cable until the red cable mark appears (about �ve wraps on the drum), then rewind the cable on to the drum under a load of 500lbs (230kg) or more. This will slightly tension and stretch the new cable and create a tight cable wrap around the drum. Failure to do so may result in cable damage and reduced cable life.
• When the cable is replaced, be sure to apply Loctite, or an equal compound, to the cable clamp thread. Tighten the clamp screw properly but do not over tighten. The Loctite will prevent loosening of the screw in arduous conditions. Loctite 7471 Primer and 222 Threadlocker are recommended.
17. DO NOT attempt to exceed the Pulling limits of this winch.
18. DO NOT drive your vehicle to assist the winch in any way. Vehicle movement in combination with winch operation may overload the cable, the winch itself or cause damaging shock loads.
19. Shock loads when winching are dangerous. A shock load occurs when an increased force is suddenly applied to the cable. A vehicle rolling back on a slack cable may induce a damaging shock load.
20. The winch shown in this manual is solely for vehicle, non-industrial applications.
21. DO NOT use winch in hoisting applications due to required hoist safety factors and features.
22. DO NOT use the winch to lift, support or otherwise transport personnel.
23. DO NOT operate and spool under full load for over one minute continuously.
24. After use, the winch will be hot. DO NOT submerge under water or drive through rivers or streams until the unit has cooled down. The IP67 level of waterproo�ng does not cover the winch when it is hot. IP67 relates to the level of waterproo�ng of the unit. IP67 covers the unit being submerged in water up to one metre for not more than 30 minutes.
NOTE: The safety precautions and instructions discussed in this manual can’t cover all possible conditions and situations that may occur. lt must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be applied by the operator.
Remote Hand Control OperationNote: It is recommended that for the initial set-up of the winch (prior to applying any load) that the winch be operated in the WIRED mode.• Before commencing any operation with the winch using the remote hand control ensure
that the isolator switch on the side of the control box is in the OFF position.• Plug the control cable (with the remote hand controller attached) into the socket on the
control box and turn slightly anti-clockwise to lock into position.• Turn the isolator switch to the ON position.• Once the winch has been set-up then the remote hand control can be operated either in
the WIRED OR WIRELESS mode.• To use the remote hand controller in the WIRELESS mode unplug the remote hand
controller from the control cable.• If at any stage during operation the remote hand controller fails to operate the winch,
reset the control box by turning the isolator switch o� then back on.• The hand control is not waterproof and care must be taken in its usage. In the event of
damage or breakage, replacement hand controls are available to be purchased through the 4x4 TOUGH® customer service helpline.
WIRELESSON/OFF switch
WIRELESSLED indicator
WIREDLED indicator
LED lightpower ON/OFF
LED light
Cable engage/disengage
8
ITEM QTY DESCRIPTION
1 1 END HOUSING, ASSEMBLY
2 1 DECAL
3 10 SOCKET HEAD CAPSCREW
4 1 DETENT SCREW
5 1 O-RING SEAL
6 1 CLUTCH LEVER
7 2 GASKET
8 1 HEX SHAFT
9 1 SUN GEAR
10 1 CARRIER ASSEMBLY, STAGE 1
11 1 CARRIER ASSEMBLY, STAGE 2
12 1 THRUST BEARING
13 1 CARRIER ASSEMBLY, STAGE 3
14 1 RING GEAR
15 4 FLANGE HEAD CAPSCREW
16 1 DRUM SUPPORT, GEAR TRAIN
16A 1 DRUM SUPPORT, MOTOR
17 2 DRUM BUSHING
18 2 TIE ROD
19 1 DRIVE SPLINED W/RETAINING RING
20 1 DRUM ASSEMBLY
21 1 BUTTON HEAD CAPSCREW
22 1 BRAKE ASSEMBLY
23 1 WIRE ROPE TERMINAL KIT
24 1 WIRE ROPE ASSEMBLY
25 1 CLEVIS HOOK
26 1 MOTOR
27 3 BOOT, ELECTRIC TERMINAL
28 1 CABLE ASSEMBLY, ELECTRIC
29 1 HEX HEAD CAPSCREW
30 1 WINCH CONTROL
31 1 TO MOTOR FIELD (BLUE)
32 1 TO MOTOR FIELD (RED)
33 1 TO MOTOR FIELD (YELLOW)
34 1 TO POSITIVE (+) TERMINAL OF BATTERY
35 1 TO EARTH MOTOR
36 1 TO EARTH MOTOR
37 1 TO NEGATIVE (-) TERMINAL OF BATTERY
38 1 REMOTE CONTROL ASSEMBLY
39 1 FAIRLEAD ROLLER
4X4 Tough® 12V DC 4WD Winch Parts List
9
4X4 Tough® 12V DC 4WD Winch Parts List
12
3
54
6
7
89
10
11
1516
A
18 17
26
28
29
22
2324
25
2019
7
39
31
21
38
14
13
12
35
3233
34
3736
30
16
17
27
10
Cont
rol c
able
Clev
is h
ook
Cont
rol b
ox
Clut
ch le
ver
Gea
r box
Mot
or
Batt
ery
isol
atio
n sw
itch
Fairl
ead
rolle
r
Rem
ote
hand
con
trol
Wiri
ng c
onne
ctio
n po
int f
or w
ired
hand
con
trol
lead
4X4 Tough® 12V DC 4WD Winch
11
Installation
CAUTION: This product should only installed by a suitably quali�ed technician. Failure to install the device correctly will void any warranty. The manufacturer will not be held responsible for damage caused to property or persons as a result of inadequate installation.
MOUNTING YOUR WINCH
1. a) The winch is to be mounted into a suitable steel mounting frame using the 4 point foot mounting system in either a horizontal or vertical plane.
b) It’s very important that the winch be mounted on a �at surface so that the three sections (motor, cable drum and gear housing) are properly aligned.
c) Before commencing installation ensure the mounting facility being used is capable of withstanding the winch’s rated capacity.
d) The �tment of winches and / or a frontal protection system may a�ect the triggering of SRS air bags. Check that the mounting system has been tested and approved for winch �tment in the airbag equipped vehicle.
2. Should you wish to manufacture your own mounting plate, the dimensions below will assist. A steel mount plate 6mm thick is recommended. Fasteners should be steel high tensile grade 5 or better. A poorly designed mount may void warranty.
3. The winch should be secured to the mounting with 3/8”UNCx1-1/4” bolts and spring washers provided.
4. The fairlead roller is to be mounted so as to guide the cable onto the drum evenly.
LUBRICATION INFORMATION
All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly. Under normal conditions factory lubrication will su�ce. Lubricate cable after each use using light penetrating oil. Inspect for broken strands and replace if necessary. If the cable becomes worn or damaged it must be replaced.
CABLE INSTALLATION
It is recommended that if the cable needs to be replaced you engage a quali�ed technician to perform this task.
AUXILIARY ITEMS (not included)
As a further safeguard, you may wish to consider installing the following items:
• An additional isolation switch on the positive lead from your battery to avoid the possibility of malicious use by an ill intentioned person.
• A second battery to avoid depleting the power of the battery that starts your vehicle, as the use of any winch draws a considerable amount of power.
15-6068 12V DC 4WD Winch - Dimensions (Dimensions are in millimetres)
165
64
218
TO-C
LEA
R
548
Front view Top view
170 254224
114
124
160
12
ELECTRICAL CONNECTION
For normal self-recovery work, your existing electrical system is adequate. A fully charged battery and proper connections are essential. Run the vehicle engine during winching operations to keep battery charged.
Pay close attention to proper electrical cable connection as follows (refer to diagrams below):
1. Short red cable (A) with red jacket connecting to the red terminal (A) of the motor.
2. Short black cable with yellow jacket (B) connecting to the yellow terminal (B) of the motor.
3. Short black cable with blue jacket (C) connecting to the blue terminal (C) of the motor.
4. Thin black cable (Earth) connecting to bottom Earth Terminal of the motor.
5. Long black cable (1.8m) one terminal connecting to the bottom Earth Terminal of the motor, and the other terminal connecting to negative (-) terminal of the battery.
6. Long red cable positive (+) connecting to positive (+) terminal of the battery.
7. It is essential that the cables are correctly connected by an experienced person who understands the wiring connection procedure. Incorrect wiring may cause the solenoid unit to cease operating. In such cases new solenoid replacements are available for purchase.
Motor - Cable connections
To motorEarth Terminal
To motor Terminal A (Red) To motor Terminal B(Yellow)
To motorEarth Terminal
To positive(+)terminal of
battery
To negative(-)terminal of
battery
To motorTerminal C
(Blue)
Terminal C (Blue)Terminal A (Red)
Earth Terminal
Terminal B (Yellow)
Control Box - Cable connections
CAUTION:
1. Your battery must be kept in good condition.
2. Be sure battery cables are not drawn taught across any surfaces which could possibly damage them.
3. Corrosion on electrical connections will reduce performance or may cause a short.
4. Clean all connections especially in remote control switch and receptacle.
5. In salty environments use a silicone sealer to protect from corrosion.
13
Winch Operation SUGGESTION:
The best way to get acquainted with how your winch operates is to make a few test runs before you actually need to use it. Plan your test in advance. Remember you can hear your winch as well as you can see it operate. Get to recognise the sound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Soon you will gain con�dence in operating your winch and its use will become second nature to you.
OPERATING:
1. Ensure the vehicle is secure by applying the parking brake or chocking the wheels.
2. Pull out the winch cable to the desired length and connect to an anchor point. A suggestion would be a tree trunk protector wrapped around a suitably sized tree which will not be damaged by the winching operation. The winch clutch allows rapid uncoiling of the cable for hooking onto the load or anchor point. The shifter tab located on the gear housing of the winch operates the clutch as follows:
a) To disengage the clutch, move the clutch lever to the DISENGAGE position. Cable may now be free spooled o� the drum.
b) To engage the clutch, move the clutch lever into the ENGAGE position. The winch is now ready for pulling.
3. Re-check all cable rigging before proceeding.
4. Plug in the winch remote hand control to the plug located on the winch control box. It is recommended that the winching operation takes place from the driver’s position to ensure safe operation. If using the wireless remote control always ensure that you are located at a distance which is greater than 1.5 times the length of the exposed cable.
5. Prepare the winch for retrieval by turning the electrical isolation switch to the on position.
6. To commence winching operation, start vehicle engine, select neutral in transmission and maintain engine speed at idle.
7. Operate the remote control switch to IN or OUT until the vehicle has been retrieved. Stop the winch regularly to ensure that the cable is winding onto the drum evenly.
8. After the recovery is complete, isolate the power to the winch by turning the electrical isolation switch to the o� position.
CAUTION:
• Check the winch carefully and thoroughly before operating.
• Never winch with your vehicle in gear or in park. This would damage your vehicle’s transmission.
• Never wrap the cable around the object and hook onto the cable itself. This can cause damage to the object being pulled, and kink or fray the cable.
• Keep hands, clothing, hair and jewellery clear of the drum area and cable when winching.
• Never use the winch if the cable is frayed, kinked or damaged.
• Never allow anyone to stand near the cable, or in line with the cable while it is under load. If the cable should slip or brake, it can suddenly whip back along the line of pull, causing a hazard for anyone in the area.
• Always stand well to the side while winding.
• ALWAYS disengage the winch when not in use.
• When not in use, the winch clutch lever is to be in the engaged position (to prevent accidental unspooling) and the electrical isolation switch is to be in the OFF position.
OFF ON
OFF
ON
ELECTRICAL ISOLATION SWITCH
OFF ON
OFFON
14
Winching PrinciplesYou need a winch to be powerful enough to pull your vehicle while overcoming the added resistance caused by obstacles, moving water, mud, snow, sand or inclines.As a general guide you need a winch with a maximum line pull at least 1.5 times greater than the gross vehicle weight. There are three factors that in�uence the line pull e�ect required to recover the vehicle. The values and calculations in this section are approximate and are for reference only.1. Gross Vehicle Weight (Wt): Contains a vehicle weight and the weight of the supplies and equipments carried.2. Surface Drag (S): The characteristics of the terrain or surface to be traversed.
SURFACE TYPE Metal Sand Gravel Soft Sand Mud MarshSurface Drag (s) 0.15 0.18 0.20 0.22 0.32 0.52
Gradient 5% 10% 20% 30% 50% 70% 100%Angle (ref.) 30 60 110 170 260 350 450Value of (G) 0.06 0.11 0.2 0.3 0.44 0.58 0.71
3. Gradient resistance: The incline of grade or slope on which the vehicle is being moved. A gradient of 10% is a rise of one metre in ten metres.
Speci�cationsRated Line Pull 12000Lbs (5443kgs) single line. Battery Leads 1.80m
Motor Series wound DC 12V with 6hp/4.5kw Fairlead 4-way roller fairlead
Gear Train Output 3 stage planetary Wire Rope 9.5mm x 26m
Gear Ratio 265:1 Drum Size 64mm x 224mm
Clutch Sliding ring gear Dimensions 548mm x 160mm x 218mm
Braking Action Automatic in the drum Net Weight 38kg (84Lbs)
Battery Recommended 650 CCA minimum for winching Mounting Bolt Pattern 254mm x 114.3mm
Line speed + motor current (�rst layer)Line pull Lbs 0 2000 4000 6000 8000 9500
Kgs 0 907 1814 2722 3629 4310Line speed FPM 25.6 16 11.9 9.79 8.01 5.9
MPM 7.8 4.88 3.63 2.98 2.44 1.8Motor current Amps 80 130 180 230 290 350
Rolling Pull E�ect required=(Wt X S) + (Wt X G) For example, if a vehicle weighing 2994 Kgs is winched by 100% on an o� road surface, the above formula would be used as follows: Wt: 2994 Kgs (gross vehicle weight) S: 0.52 (co-e�cient for surface) G: 0.71 (gradient value of 100%)(Wt X S)+ (Wt X G) = 1557 Kgs + 2126 Kgs = 3683 Kgs of e�ect required to recover the vehicle
5443Kgs/12000LBS Line Pull and Cable Capacity Table
Layer of cable 1 2 3 4 5
Rated line pull per layer
Lbs 12000 9550 8000 6800 6000
Kgs 5443 4332 3629 3084 2722
Cable capacity Ft. 16 36 61 90 100
M 4.9 11 18.6 27.4 30.5
Note: This guide is recommended for average vehicle rolling loads. Some applications may require a larger winch than indicated.
15
Battery ReplacementThe hand control is supplied with a non rechargeable Alkaline 23A 12V battery within the hand control and a spare battery if it requires changing.
CAUTION:
• Keep battery out of reach of children.• If a child swallows a battery seek medical advise immediately.• Do not use any metallic devices to install battery - this may cause a short circuit.
Battery
Figure 1. Figure 2. Figure 3.
Remote handcontrol
• To open remote hand control unscrew 4 screws and carefully pull apart the two halves.
• To access the battery, pull o� the IN/OUT toggle switch assembly which is inserted into the 6 recesses on the circuit board. Bend the front of the printed panel forward. Once the battery is replaced (ensuring the polarity orientation is correct. ie: Match + to +), put back the IN/OUT toggle switch assembly and reassemble the hand control.
Receiver Component Replacement
Figure 7. Figure 8. Figure 9.
Receivercomponent
Control box
• To open control box unscrew 4 screws and carefully lift the lid.
• Gently lift out old Receiver Component (do not pull out by the wiring) and unplug. Insert replacement Receiver component.
PLEASE CONTACT THE AFTER SALES SUPPORT TEAM IF REPLACEMENT PARTS ARE REQUIRED.
16
MaintenanceIt is highly recommended that the winch be used regularly (once a month). Simply power the cable out 15m, free spool 5m [a total of 20m] and then power back in. This will keep all components in good working condition.
All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly. Under normal conditions factory lubrication will su�ce. Lubricate cable after each use using light penetrating oil. Inspect for broken strands and replace if necessary. If the cable becomes worn or damaged it must be replaced.
CAUTION:
1. Your battery must be kept in good condition.
2. Be sure battery cables are not drawn taught across any surfaces which could possibly damage them.
3. Corrosion on electrical connections will reduce performance or may cause a short.
4. Clean all connections especially in remote control switch and receptacle.
5. In salty environments use a silicone sealer to protect from corrosion.
It is also recommended to have your winch serviced every 12 months to keep the unit in optimum working condition. Your 4x4 TOUGH® winch should only be serviced by quali�ed persons. Examples include, quali�ed mechanics, auto electricians and engineers. The winch should be removed from the vehicle prior to beginning the service. Please ensure genuine parts are used for any spare parts that may be required during the service. Contact the customer service department on 1300 883 104 if necessary to obtain parts under warranty. Photographs of faulty parts are recommended to support warranty claims. Please email these to [email protected]
Disposal • Please consider when disposing of electronic products such as a winch that some components can be recycled and recovered
for re-use. Do not attempt to dissemble any electronic product unless you are a trained electronics technician.
• Many councils hold e-waste (electronic waste) collections. Contact your nearest council to enquire about the best method of disposal in your area.
FAQQ: How much rated line pull do I need?
A: Rated line pull refers to the maximum amount of weight that a winch can shoulder, so you need a winch with enough strength to handle your vehicle’s weight. Thankfully, there is a simple formula for calculating the correct rated line pull: Gross Vehicle Weight x 1.5 = Minimum Rated Line Pull.
Q: Can I remove my winch?
A: Yes. During the o� season, you can unbolt your winch and leave it at home. Some mounts make it easy to remove the winch, and some require a bit more e�ort. Hitch mounts and grille guard mounts are the easiest since the winch is so accessible. In a hidden, semi-hidden or replacement bumper setup, the winch sits behind or below the bumper, so removal can be tricky.
Q: Can I operate my winch wirelessly?
A: Yes. While all winches come with a wired remote control, your 4x4 TOUGH® Winch also operates wirelessly with maximum ranges of between 25 and 30 metres. Refer to the operating instructions on page 13 within this manual.
Q: What’s the di�erence between electric and hydraulic winches?
A: The basic di�erence between an electric and a hydraulic winch is the power source. Electric winches link to the vehicle’s battery, whereas hydraulic winches are driven from the power steering pump. Electric winches are the most prevalent in the market place and as such greater choice is available. They have the advantage of being able to operate without the vehicle running, however as they draw signi�cant power from the battery it is recommended the vehicle be running whilst winching operations are underway. Electric winches generate signi�cant heat and it is important they be run for only short periods of time before being rested to cool down. Hydraulic winches are able to operate on a more continuous basis, however they can only operate if the vehicle is running.
