RED Winches HORNET 2 WORKSHOP MANUAL WITH DRAWINGS

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1 WORKSHOP MANUAL WITH DRAWINGS This winch is part of a group of winches whose designs have undergone extensive testing. The end user can now enjoy a professional highly engineered high performance electric winch capable of operating in the most demanding of situations.the small compact size combined with its pulling power make it an ideal winch for maximum impact when faced with minimal installation space WORKSHOP MANUAL ULTIMATE PERFORMANCE 1:3 A OF 12 1

2 REV. DATE DESCRIPTION SIG A 05/02/2017 WORKSHOP ISSUE NJ MIN PLATE THICKNESS UNLESS SPECIFIED FASTENER M6 M8 M10 M16 M20 TORQUE 10 Nm 20 Nm 35 Nm 65 Nm 130 Nm 180 Nm WARNING: MOUNTING PLATE THICKNESS IS IMPORTANT IN SAFE, RELIABLE OPERATION OF THE IF THE THICKNESS IS LESS THAN 8mm IT MAY DAMAGE THE AND INVALIDATE ANY WARANTY ON THE. ULTIMATE PERFORMANCE DIMENSIONS 1:5 A OF 12 2

3 Grease Specification: Castrol Spherol L-EP 2 or BP Energrease LS-EP 2 MOTOR ASSEMBLY MOTOR GEAR HORNET2-MD-21 BRAKE UNIT INTERMEDIATE GEAR HOUSING GEARBOX HOUSING FREESPOOL HORNET2-MD-20 2X HORNET2-MD-22 DRIVE GEAR HORNET2-MD-24 FRONT FASTENING BOLTS 8off IN TOTAL. STANDARD GEARSET SHOWN SHAFT GEAR SMALL AMOUNT OF GREASE TO BE APPLIED ON SPLINE FOR LUBRICATING ON ASSEMBLY SMALL AMOUNT OF GREASE TO BE APPLIED ON DRIVE DOG WHEN ASSEMBLED M5 SKT CAP HEAD SCREWS REMOVE THESE TO ACCESS THE GEARBOX M5 SKT CAP HEAD SCREWS REMOVE THESE TO ACCESS THE FREESPOOL AND DRIVE SHAFT BRAKE UNIT REMOVED FOR CLARITY CAN BE MOUNTED EITHER ON THE FRONT OR THE LOWER FACE. IT IS NOT NECESSARY TO USE FRONT AND LOWER MOUNTED BOLTS. UNLESS SPECIFIED FASTENER M6 M8 M10 M16 M20 TORQUE 10 Nm 24 Nm 45 Nm 80 Nm 160 Nm 200 Nm ENSURE ALL FASTENERS ARE TORQUED TO THE CORRECT VALUES LOCTITE 234 (THREADLOCKER) TO BE APPLIED ON ALL FASTENERS LOWER FASTENING BOLTS 8off IN TOTAL. ULTIMATE PERFORMANCE REMOVING BRAKE & MOTORS 1:3 A OF 12 3

4 Grease Specification: Castrol Spherol L-EP 2 or BP Energrease LS-EP 2 CLUTCH PLATE TO REMOVE CLUTCH PLATE: REMOVE CLUTCH PLATE PINS FIRST ENSURE ALL FASTENERS ARE TORQUED TO THE CORRECT VALUES LOCTITE 234 (THREADLOCKER) TO BE APPLIED ON ALL FASTENERS UNLESS SPECIFIED FASTENER M6 M8 M10 M16 M20 TORQUE 10 Nm 24 Nm 45 Nm 80 Nm 160 Nm 200 Nm AIR FEED NOZZLE PISTON WITH O-RINGS FITTED GREASE SPLINE WITH COPPER SLIP ONLY RETAINING PINS ENGAGE SPRING MAIN DRIVE SHAFT SPECIAL TOOL REQUIRED TO COVER UP SLOT EDGE INTERNALLY WHEN INSERTING PISTON TO PROTECT O-RINGS KEYWAYS TO BE A FIRM PRESS FIT. JACKING SCREW USED TO REMOVE THEM DUCK OIL OR LIGHT ENGINEERING OIL ONLY ENGAGEMENT SLOTS x 4 GREASE COPPER SLIP GREASE TO BE APPLIED ON SPLINE TO REMOVE CLUTCH PLATE PINS: LOSEN BOLTS (x2) ON FRONT OF CLUTCH PLATE ULTIMATE PERFORMANCE FREESPOOL DETAILS 1:3 A OF 12 4

5 WARNING: _QSLV-1_8-6-I ONLY REMOVE BRAKE DISC SCREWS WHILE THE AIR IS ON. AIR MUST BE APPLIED TO THE UNIT TO TAKE PRESSURE OFF THE BRAKE PADS BEFORE ATTEMPTING TO REMOVE SCREWS _AMTE-M-H-M5 ABU-MD-01 AIR FEED FOR BRAKE FROM AIR BRAKE SOLENOID VALVE O-RINGS MUST BE ALL LIGHTLY OILED BEFORE ASSEMBLY N228 HIGH TEMPERATURE O-RINGS MUST BE USED ABU-MD-02 N230 ABU-MD-03 4X M4 x 16 6X ENTEX-91 3X ABU-MD-05 ABU-MD-07 2X ABU-MD-06 ABU-MD-08 3X M5 x 16 ABU-MD MN036X2.5 C M4 x 16 4X BRAKE PAD UNLESS SPECIFIED FASTENER M6 M8 M10 M16 M20 TORQUE 10 Nm 24 Nm 45 Nm 80 Nm 160 Nm 200 Nm ENSURE ALL FASTENERS ARE TORQUED TO THE CORRECT VALUES LOCTITE 234 (THREADLOCKER) TO BE APPLIED ON ALL FASTENERS ULTIMATE PERFORMANCE BRAKE ASSEMBLY 1:2 A OF 12 5

6 ALUMINIUM END CAP 18 3 CLAMP PINS SREW INTO GEARBOX HOSUING OF WITH EACH MOTOR YOU WILL RECIEVE: 2 x M6 PINS 2 x 1/4" UNC PINS 8 1 BRUSH PACK FITTED TO THE BACK SIDE OF THIS FRONT END CAP ULTIMATE PERFORMANCE MOTOR ASSEMBLY 1:2 A OF 12 6

7 With the appropriate battery and alternator system, these OX Motors will provide tremendous pulling power and a very high drum speed at no-load when respooling the rope back on to the drum. Never allow the OX MOTOR to over speed or run in a no-load situation for too long as the armature could become damaged through revolving too fast. RED ES BUS BAR COVER ALBRIGHT SOLENOIDS HEAVY DUTY M8 EARTH CONNECTION x 3 POSITIVE CONNECTION AIR BRAKE SOLENOID USE SMALL ZIP TIE TO HOLD THE COVERS DOWN WHEN USED ON ROUGH TERRAIN OR TRAVELLING AT HIGH SPEED O-RING IN END PLATE BRUSH PACK IN FRONT OF MOTOR EXHAUST AIR COMES FROM TOP RED ES BUS BAR SET 151 UNLESS SPECIFIED FASTENER M6 M8 M10 M16 M20 TORQUE 10 Nm 20 Nm 35 Nm 65 Nm 130 Nm 180 Nm ENSURE ALL FASTENERS ARE TORQUED TO THE CORRECT VALUES LOCTITE 234 (THREADLOCKER) TO BE APPLIED ON ALL FASTENERS ULTIMATE PERFORMANCE MOTOR ASSEMBLY 1:3 A OF 12 7

8 12v OR 24v POSITIVE WIRE FROM YOUR TRUCK GOES HERE. TO FEED MOTORS ALBRIGHT SOLENOID: DC PL (12V) ALBRIGHT SOLENOID: DC PL (24V) 70mm2 MINIMUM IDEALLY 100mm2 OR GREATER M8 CONNECTION TWO CABLES CAN BE CONNECTED AIR BRAKE SOLENOID AIR FEED FOR AIR BRAKE SOLENOID EARTH / NEGATIVE WIRE FROM YOUR TRUCK GOES HERE. TO FEED MOTOR. 70mm2 MIN IDEALLY 100mm2 OR GREATER M8 CONNECTION TWO CABLES CAN BE CONNECTED MUST GO BACK TO YOUR BATTERIES DIRECTLY TO GIVE BEST POSSIBLE PERFORMANCE 12v & 24v SETUP WITH SOLENOIDS IF YOU ARE RUNNING YOUR POWER TO THE MOTORS ON 24v THEN YOU DO NOT NEED 24v SOLENOIDS. THE 24v POWER WILL TRANSFER THROUGH THE SOLENOIDS TO THE MOTORS IF YOU ARE RUNNING 24v ON YOUR VEHICLE SYSTEMS AND SIGNALS THEN YOU WILL NEED 24v SOLENOIDS AND A 24v AIR SOLENOID AS THESE ARE ONLY RATED AT 12v NORMALLY FOR SIGNAL VOLTAGE ULTIMATE PERFORMANCE MOTOR ASSEMBLY 1:3 A OF 12 8

9 HORNET2-MD-04 1x L x SC30X40X4 1x x HORNET2-MD-12 1x HORNET2-MD-11 1x MOTOR ASSEMBLY AIR BRAKE UNIT 2x 1x 1x N109 1x N809 HORNET2-MD-13 HORNET2-MD-10 HORNET2-MD-14 2x 8x 8x x 30 FORM C 2x VL170 SEAL 2x RS HORNET2-MD-06 1x x 4202-ATN9 4x M5 x 10 4x HORNET2-MD-20 2x HORNET2-MD-21 1x HORNET2-MD-20 2x HORNET2-MD-23 1x 1x HORNET2-MD-07 HORNET2-MD-22 1x x 2x HORNET2-MD-16 8x x 50 HORNET2-MD-02 1x M5 x 16 24x 3x x HORNET2-MD-18 4x HORNET2-MD-08 1x HORNET2-MD-05 1x HORNET2-MD-01 4x 4202-ATN x HORNET2-MD-24 1x 3x 4x 4x ATN ATN9 ULTIMATE PERFORMANCE ASSEMBLY 1:3 A OF 12 9

10 Lubrication Details Grease Specification: Castrol Spherol L-EP 2 or BP Energrease LS-EP 2 As a guide grease must be applied to the gears in the end housing when serviced The lubrication frequency is based on irregular winch usage in hours per month: 1-15 Hrs - Add grease and cover gears every 12 Months Hrs - Clean and Replace Grease Every 6 Months This above based on dry above water level conditions. If winch has been used within water or wet muddy ground for more than 50% of the hours specified the greasing / servicing frequency needs to be: 1-15 Hrs - Add grease and cover gears every 6 Months Hrs - Clean and Replace Grease Every 3 Months GREASE APPLIED TO THESE GEAR TEETH ANY RESIDUE OR LIQUID FOUND IN THE LOWER PART OF THE CASE CAN BE REMOVED. ULTIMATE PERFORMANCE GREASE / LUBRICATION 1:1.75A OF 12 10

11 Safety - Hornet Winch This winch is part of a range of winches produced by Ltd that are designed for high speed and high power. This winch will pull rope onto its drum quickly and with power. If operated without care and attention this winch could easily damage fingers, hands and in some cases eyesight. The winch is powered by DC voltage, in most cases 12v, but also 24v systems can be used to power the winch. The current draw on this DC voltage can be high so care and attention must be taken when operating the winch that the electrical power to the motors is not exposed to the operator. The winch should only be operated by a person who has been authorised to do so or has been trained to operate it safely. Safety Instructions - Hornet Winch WARNING! THIS IS ONLY SUITABLE FOR ING SITUATIONS / APPLICATIONS WARNING! Ensure all fasteners and connections are adequately connected or secured before using the winch Maintain the equipment in good condition (use an authorised servicing agent if required) Replace or repair damaged parts. Use genuine parts only. Unauthorised parts may be dangerous and will invalidate any warranty. Use a qualified person to lubricate if required and maintain the equipment. Before use, ensure all parts are clean and free of contamination / dirt. DO NOT use solvent cleaners to clean this winch Use the equipment in a suitable work or operational area, keep winching area clean and tidy and free from unrelated materials, and ensure that there is adequate lighting while setting and operating the winch. Keep the winch and winch rope clean for best and safest performance. The maximum line load is 4500kg. DO NOT exceed this rated capacity. When operating remove ill-fitting clothing. Remove ties, watches, rings and other loose jewellery, and contain long hair. Maintain correct balance and footing, do not over reach. Ensure the floor / ground is not slippery and wear appropriate footwear. Before using the winch check that there are no overhead or surrounding obstructions. The speed during operation must be kept steady and constant. Do not generate sudden movements or shock loads. DO NOT use the winch for a task it is not designed to perform. DO NOT use the equipment if damaged. DO NOT exceed the rated capacity of the equipment. DO NOT use the equipment when you are tired or under the influence of alcohol, drugs or intoxicating medication. DO NOT allow untrained persons to use the equipment unsupervised DO NOT attempt to transport a load outside JLR designated safe load / unload areas. DO NOT make any modifications to the equipment DO NOT operate the winch and handle the synthetic rope without approved winching gloves and appropriate PSE The Winch The winch is an excellent choice when it comes to speed and power for electric winching. It has been designed specifically for high performance and durability. The winch can give you speeds of 50m/min for the standard model, and 65m/min with the Hornet Overdrive gear set (available separately) giving you a choice so you have the power and speed when you need it. The winch body is CNC machined from high grade heat treated aerospace aluminium from solid billets. Its patented brake system offers something previously unavailable on a winch and ensures the winch stops instantly when your finger it taken off the winch control button. You can also have the Hornet come with the Overdrive Kit which makes it 1.5 times faster... his is free if you specify it at the time of ordering. The winch air brake system: Springs apply pressure to a steel disc which then applies pressure to the brake disc and its material when the winch is not in use. This applies the brake and stops the winch drum from moving under load and from spooling out the rope. An air solenoid for the air brake is fitted next to the motors at the top of the winch. This is fed by an air supply from the ARB compressor. When you winch in or out you energise your Albright motor solenoids this also energises the air solenoid valve for the brake on top of the winch. This then allows air to go into a specially designed chamber that releases the brake instantly. When you remove your winching finger from the controls the air solenoid dumps the air and the springs apply the brake disc onto the brake pads. This means compared to normal winching you do not get overrun or excess rope causing snatching and jerking as the vehicle takes up the slack rope that has been spooled out. This design has been submitted for full patent and is currently protected and patent pending. The electrical power of this winch is currently supplied by two OX Motors, 12v (7HP). These are supplied normally with a 12v supply from your vehicle onto the high efficiency copper busbar assemblies found on top of the motors. The high power Albright motor solenoids are used to switch direction of the motors and at the same time provide a feed to the 12v brake system via their signal terminals. Drum The drum is mechanically driven by a solid steel hardened clutch plate. This is a very tough hardened plate. The clutch plate is driven from the gearbox by a solid steel central shaft passing through the middle of the drum. The drive system has been built for strength and durability. All our winches are now supplied with Plasma Locks to hold the synthetic rope onto the drum, proven method and very reliable. It is a nice simple solution to ensure you always have the minimum amount of line wraps on your winch drum. With the Plasma Lock installed you can pull your rope line out with confidence that it won't leave you without any line on the drum! The Plasma lock has been designed for a variety of line gauges and you can feel confident that at least 8-10 wraps remain on your drum, reducing greatly the chances of a slippage. The Plasma Lock is made from double thickness, heavy duty bright red webbing and is 150mm x 40mm (approx). Gearbox The gearbox has been specifically designed for strength, power and ease of service. All gears are manufactured from 655-M13 nickel chromium molybdenum steel and case hardened to give maximum strength (1100 N/mm²) and excellent durability. The end covers are sealed via an o-ring and groove, ensuring a watertight seal. Once the cover is removed access to all gears is possible and only takes a short time to service and re-assemble. The gearbox runs in grease not oil making it much easier to service in the field. Set-up Procedure (1) Check winch as per the safety instructions (2) Check winch is situated correctly for the task at hand (3) Check rope is on drum securely and is not tangled (4) Check power connection to winch (5) Ensure Compressor is on and the winch has air pressure to it (6) Winch is now ready to operate Startup The winch can release and winch line in at 40m/m or faster, this is much faster than a normal winch The winch gearbox has gears that are straight cut for strength and durability The winch gearbox is noisier than other winches due to the rotational speeds of the gears, especially when not under load. The compressor will run and vibrate whenever it needs to topup the air in the system, the winch uses very little air to operate. This compressor could start when the winch is not being operated if the air pressure in the system drops Q & A Q: How do I store the rope on the drum? A: Always leave the drum and rope neatly spooled after use with the rope clean and evenly layered Q: What should I do if the winch has been used in muddy / wet / dirty conditions A: After a prolonged dirty wet operation clean and wash the rope and clean all connections Q: What if the winch stops while operating? A: If the winch overloads, i.e. it stops under load, release the control button immediately and assess the situation otherwise you could damage the motors. Check all electrical connections to ensure they are secure and look normal.

12 DESCRIPTION ALL BOLTS AND SCREWS FITTED CORRECTLY COMPLETED YES / NO NOTES ALL BOLTS AND SCREWS (APART FROM THOSE INDICATED) SECURED WITH LOCTITE 234 ALL BOLTS AND SCREWS FITTED CORRECTLY AND TIGHTENED TO THE CORRECT TORQUE SETTING GEARS FULLY GREASED AND MINIMUM OF 1" OF GREASE IN LOWER PART OF CASE AIR BRAKE ASSEMBLY LIGHTLY GREASED AND ALL O-RINGS FITTED. AIR BRAKE ASSEMBLY FULLY TESTED TO ENSURE BRAKE PADS ARE FREE TO ROTATE WITH NO HIGH SPOTS WHEN AIR IS APPLIED AND THE BRAKES ARE OFF. AIR SOLENOID CHECKED FOR LEAKS. ENSURE THREADLOCKKING IS NOT LEAKING AIR AIR FREESPOOL GREASED ON SPLINE AND DISC. DUCK OIL APPLIED INTERNALLY ON O-RINGS AND PISTON. AIR FREESPOOL FUNCTION TESTED AT LEAST 20 TIMES. TO WORK EVERY TIME OTHERWISE STRIP DOWN AND CHECK. WIRING TESTED PRIOR TO ASSEMBLING ON. POWERED AND TESTED IN BOTH DIRECTIONS. AIR FREESPOOL AND BRAKE SOLENOID CHECKED TO ENSURE CORRECT OPERATION. BUS BAR ARRANGEMENT CHECKED FOR CONTINUITY. ZIP TIES FITTED ON COVERS NAME OF ENGINEER BUILT / PERFORMED FINAL CHECKS SIGNATURE SERIAL NUMBER ULTIMATE PERFORMANCE REPORT INSPECTION SHEET, FINAL BUILD CHECK SHEET HORNET2-STD 1:5 A OF 12 12