Electric Winch Installation & Operation Manual Permanent Magnet 12 V DC EMD2000SS STAINLESS STEEL WINCH

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1 Endurance Marine Products Ltd Ave Surrey, BC V3S 3V7 T TOLL FREE Info@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 1

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) 2

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 3

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 4

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6 WINCH OPERATION 1. CLUTCH OPERATION: The clutch is operated by pulling out the Clutch Knob (part#6) and rotating it about 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 6

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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 Water has entered motor Check for voltage at armature port with switch pressed. If voltage is present replace 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 MANUFAC TURER 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. 8