RED Winches COBRA - SINGLE MOTOR WINCH WORKSHOP MANUAL WITH DRAWINGS

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1 COBRA - SINGLE MOTOR WINCH 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. REDWINCH COBRA - WORKSHOP MANUAL 1

2 REV. DATE DESCRIPTION CHANGED BY A 01/12/2015 PRODUCTION ISSUE NJ 6mm AIR TUBE FEEDS BRAKE SOLENOID HERE MINIMUM MATERIAL THICKNESS OF 8mm TO BE USED FOR WINCH TRAY OR MOUNTING PLATE 40.5 NETT WEIGHT: 30 Kg PACKED WEIGHT: 35Kg 114 MOUNTING BOLTS x 4 UNLESS SPECIFIED FASTENER M6 M8 M10 M12 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 WHEN WINCH IS FITTED RED WINCH COBRA - DIMENSIONS / LAYOUT 1:5 OF 9 2

3 BUS BAR COVER EARTH TO BATTERY GOES HERE: M8 BOLT AIR BRAKE PNEUMATIC CONNECTION 6mm TUBE (AIR IN) 12v OR 24v OX MOTOR AIR BRAKE ASSEMBLY ALBRIGHT MOTOR SOLENOID AIR BRAKE SOLENOID REAR VIEW FRONT FREESPOOL END COVER LEFT SIDE POSITVE CONNECTION FROM YOUR BATTERY (70mm² CABLE MIN) AIR BRAKE PNEUMATIC CONNECTION (AIR IN) END HOUSING CAN BE ROTATED TO SUIT MOUNTING FOR YOUR TRUCK TOP VIEW F1 MOTOR END COVER F2 A AIR FREESPOOL PNEUMATIC CONNECTION 6mm TUBE (AIR IN) COPPER BUS BAR SET GIVING (75mm2) COVER REMOVED TO SHOW BUS BAR ARRANGEMENT ALUMINIUM FAIRLEAD SPEED: 21m/MIN (12V SUPPLY - 12v BOW 2) 36m/MIN (24V SUPPLY - 12V BOW 2) PULL: POWER: BRAKE: FREE-SPOOL: 4500KG 12 or 24vDC AIR (MIN 5 BAR - 70psi) AIR (MIN 5 BAR - 70psi) RED WINCH COBRA - FEATURES AND COMPONENT PARTS 3

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5 FREESPOOL END COVER FREESPOOL END HOUSING AIR BRAKE SOLENOID TIE BAR MOTOR ASSEMBLY AIR BRAKE GEARBOX HOUSING DRIVE HOUSING MOUNTING BLOCK FAIRLEAD DRUM ASSEMBLY JACKING SCREWS TO REMOVE COVER GEARBOX DRIVE HOSUING COVER RED WINCH COBRA - EXPLODED VIEW 5

6 12v or 24v POSITIVE FEED FROM YOUR VEHICLE M8 BOLT CONNECTION (70mm² CABLE MINIMUM) DETAIL B 1 : 1.5 NOTE: AIR BRAKE MUST BE RELEASED AT THE SAME TIME THE WINCH IN OR WINCH OUT SIGNAL IS GIVEN THIS IS WHAT THE DIODE WIRE ASSEMBLY DOES FOR THE WINCH EARTH TO BATTERY M8 BOLT 12v SIGNAL WINCH IN (BROWN WIRE) EARTH CONNECTION (BLACK WIRE) 12v SIGNAL WINCH OUT (RED WIRE) AIR FREESPOOL CONNECTION 6mm TUBE (2m PROVIDED) RED WINCH COBRA - HOW TO OPERATE 6

7 OX ITEM NO. DESCRIPTION MOTOR/ Default/Q TY. 1 COBRA END HOUSING ASSEMBLY 1 2 DRIVE SHAFT & FREESPOOL ASSEMBLY 1 3 COBRA WINCH BODY ASSEMBLY 1 4 HAWSE FAIRLEAD 1 5 MOUNTING FOOT - VIPER 2 6 LOCATION COLLAR 6 7 M10 x 40 CAP HD SCREW 8 8 M10 x 25 SKT CP HEAD 8 9 M12 x 40 CAP HD SCREW 4 10 WASHER 4 11 SINGLE MOTOR BRAKE ASSEMBLY 1 12 COBRA WINCH DRUM ASSEMBLY - STD 1 13 OX MOTOR ASSEMBLY 1 14 AIR SOLENOID 1 15 AIR SOLENOID BRACKET RED WINCH COBRA - PARTS LIST 1:4 OF 9 7

8 Lubrication Details Grease Specification: Gearbox Castrol Spherol L-EP 2 or BP Energrease LS-EP 2 Grease Specification: Freespool Shaft Duck Oil for internal Piston Copper Grease for External Spline As a guide Grease must be applied to the gears in the end housing and air freespool clutch plate as per the following: The lubrication frequency is based on constant winch usage in hours per month: 1-4 Hrs - Add grease and cover gears every 6 Months 4-12 Hrs - Add grease and cover gears every 4 Months This is 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 frequency needs to be increased to half of those shown in the above chart. Every 12 months the internals of the winch gearbox and freespool should be cleaned and the grease should be replaced. Important: Freespool must be cleaned and internal parts sprayed with duck oil after the winch has been submerged in mud or water for long periods of time. The gearbox must also be inspected for water ingress and greased if necessary. GREASE SHEET 8

9 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 GEARBOX CASE MOTORS CHECKED FOR FUNCTION & QUALITY FREESPOOL ON DRUM IS FREE AND EASY TO TURN AIR FREESPOOL CONNECTION CHECKED FOR LEAKS 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. CORRECT BOLT LENGTHS HAVE BEEN USED ADN ALL MOUNTING HOLES ARE CLEAN AND FREE FROM DIRT WINCH POWERED AND TESTED IN BOTH DIRECTIONS. AIR FREESPOOL AND BRAKE SOLENOID CHECKED TO ENSURE CORRECT OPERATION. NAME OF ENGINEER BUILT / PERFORMED FINAL CHECKS SIGNATURE WINCH SERIAL NUMBER PUMP TYPE COBRA INSPECTION SHEET PUMP DESCRIPTION: ELECTRIC LOW LINE WINCH COBRA XL WINCH ULTIMATE PERFORMANCE WINCH REVISION 1:5 A OF 9 9