electric winch installation & operation manual permanent ... · electric winch installation...
TRANSCRIPT
1
Endurance Marine Products Ltd
210—19138 26 Ave Surrey, BC V3S 3V7
T 604 535 0669 TOLL FREE 1 877 535 0669
www.endurance-marine.com
Electric Winch
Installation & Operation Manual
Permanent Magnet
12 V DC
EMD2000SS STAINLESS STEEL WINCH
TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE
Due to continuing improvements, actual product may differ slightly from the product described herein
2
The Endurance winch is powered by a 1.5 hp permanent magnet motor designed for intermittent general
duty use. It is not designed as an industrial hoist or to be used in the movement of people. A free spool
clutch disengages the gear box to allow cable to be manually pulled out. A tension plate eliminates fouling
the cable and spools evenly
FEATURES
Fast line speed
Low electric current draw
Automatic load-holding brake
Power In and Power Out
Rated Line Pull 2000 lbs (907kgs), Single Line
Gear Reduction Ratio 153:1
Motor (permanent magnet) 1.5 hp (1kw), 12 Volt DC
Drum Size (Diameter x Length) (Stainless Steel) 1.26” x 2.8” (32mm x 71mm)
Drum Flange (Stainless Steel) 3.78” (96mm)
Cable Supplied (Stainless Steel) min. break force 4000 lbs 5/32” x 35’ (4mm x 10.6m)
Hook (Stainless Steel) 3/16”
Overall Dimensions (L X W X H) 12.6” x 4.13” x 4.35” (320mm x 105mm x 110.5mm)
Net Weight 14.6 lbs (6.6 kg)
Mounting Bolt Pattern 1.89” x 3” (48mm x 76mm)
3
SAFETY WARNINGS & PRECAUTIONS
1 Do not operate winch under influence of drugs or alcohol
2 Read manual before using any winch
3 Always use heavy gloves when handling wire rope
4 Never hook the cable back upon itself. The cable can break under tension and cause injury and damage.
See Figure 1
5 Stay clear of wire rope and keep others away when in operation or with load on wire. Do not stand in line
with a cable under tension
6 Inspect winch and wire rope before each use. Do not use winch if wire rope or winch shows wear or
damage
7 Replace any parts as needed before using the winch
8 Do not exceed the winch capacity and always have 5 wraps of cable on the drum
9 Do not place hands near the fairlead when winch is in operation. Always use the protective hand-saving
belt when spooling. See Figure 3
10 Do not use the winch as a hoist or to move people
11 Do not use winch to secure a load or tow vehicles
12 Do not submerge winch in water
13 Avoid injury and property damage, be safe and think first before operating winch
14 Look to see where the drill bit will come through before drilling holes for installation
15 Never drill into the gas tank or electrical wiring
16 Place towel or sandbag over wire while winch is in use
17 Do not allow winch to overheat. If hot or is too warm to touch, allow to cool down
4
SAFETY WARNINGS & PRECAUTIONS (continued)
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.
CAUTION
Keep hands clear of wire rope, hook and fairlead opening during operation. Always use handsaving belt to hold hook when spooling
INSTALLATION INSTRUCTIONS
When installing the Endurance winch, your installation may vary from the manual diagrams and instructions included here due to
vehicle and mounting operation in the structure. Always disconnect the battery from the vehicle to remove the electrical hazard
CAUTION
You may be required to drill holes in a structural support. Be sure the location will be strong enough to support the
rated pulling force of the 2000lb winch. Do not drill into wiring or gas tank! If the mounting bolts needed are a
different length than those supplied, use a bolt of equal or better quality. Torque the kit’s 5/16” Grade 5 mounting
bolts to 12 ft lbs (1.7kg-m)
1 Prepare a flat and secure location for the winch
2 Position the winch over the mount and check for the operation of the clutch lever to frame clearance. Check for tire
to winch clearance. If ok, continue on to the next step
3 Secure the winch to the mounting bracket or surface chosen with the correct hardware
NOTE: make sure the winch mounting bolts and winch hardware have been checked for proper torque
4 Connect the wiring as shown in Figure 9 and double check each wire connection for correct position. Tie down the
wire as needed for a clean look and dependable service
CAUTION
When attaching wires to the motor terminals, hold the inner nut with a second wrench to avoid the terminal from
rotating in the housing. This will help avoid internal wire breakage. Connect the black wire to the battery last
NOTE: if the battery is of a type that will not accept the supplied terminals, you may have to find the correct
adapters at a local automotive store
CAUTION
Always use the safety hook strap when the hook is near the fairlead or winch drum
5 Before testing the Endurance winch, pull and turn the clutch handle to the free position. Always wear heavy gloves
when handling heavy wire rope. Pull about 2 feet of wire rope off the winch and place the clutch handle in the
engaged position. See figure 6
5
6
WINCH OPERATION
1. CLUTCH OPERATION: The clutch is operated by pulling out the Clutch Knob (part#6) and rotating it about 45-90
degrees, see Figure 6. This will allow you to freespool the winch. Turn Clutch Knob (part#6) until it pops back into
place this makes it go fully in gear
CAUTION Never release the wire rope while under tension. Doing this can badly damage the winch and/or cause
property damage and serious injury
2. Wire Rope Handling: Grab the Hook with Pulling Belt (part#21) and pull the wire rope to the desired length, then attach the hook to item being pulled. Make sure the hook’s spring-loaded latch is set
CAUTION Always leave at least five turns of wire rope on the drum. Review Winch Safety Warnings & Precautions before continuing
3. While standing aside of the tow path, press (and hold) the push button on the remote control to pull the load. If the load will not move, release pull switch and check for obstacles blocking the load, or check to see if load is too heavy for winch capacity
CAUTION This 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 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. Do not maintain power to the winch if the motor stalls as it can damage the motor or gear
NOTE: A fully charged battery will give best service. The engine should be kept running during operation
MAINTENANCE
1. All moving parts within the winch have been lubricated using high temperature lithium grease at the factory. No
internal lubrication is required
2. Lubricate wire rope periodically using a light penetrating oil
Wire Rope Assembly replacement (to be performed only by a qualified service tech)
1. Move Clutch Knob (part#6) to the OUT position
2. Extend Wire Rope Assembly (part#20) to its full length, Note how the existing Wire Rope is connected to the inside
of the drum
3. Remove old Wire Rope Assembly and attach new one
4. Retract Wire Rope onto Drum (part#14) being careful not to allow kinking
GENERAL
1. Keep vehicle battery in good condition
2. Be sure that the winch battery cable is not drawn tight against any surfaces which could possibly damage it
3. Periodically remove and clean cable connections to the battery fuse box and chassis ground. Corrosion will reduce
performance or may cause short
4. Cover the cables and winch when not in use
7
8
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE SUGGESTED REMEDY
Motor does not turn on Switch assembly not connected
properly
Insert switch assembly firmly into the
connector
Loose battery cable connection Tighten nuts on cable connectors
Defective switch assembly Replace switch assembly
Defective motor Check for voltage at armature port
with switch pressed. If voltage is
present replace motor
Water has entered motor Drain and dry. Run in short bursts
without load until completely dry
Motor runs too hot Long period of operation Let winch cool down periodically
Motor runs slowly or without normal
power
Battery run down Recharge battery by running vehicle
engine
Insufficient current or voltage Clean, tighten or replace the
connector
Motor runs, cable drum does not turn Clutch not engaged Push clutch knob (part#6) into IN
position. If that does not work, ask a
qualified technician to check and
repair
Motor runs in one direction only Defective switch assembly Replace switch assembly
PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE
TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF
ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR
SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR
EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF
HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR
HER INSTALLATION OF REPLACEMENT PARTS THERETO.