INSTRUCTION MANUAL 95/ LBS. WINCH MODEL: D95SC / D95SR / D95SRD DSC / DSR / DSRD www.aprveatv.cm 95/ LBS. 95/ LBS. D95SC / DSC D95SR / DSR D95SRD / DSRD
As yu read these instructins, yu will see WARNINGS and CAUTIONS. Each message has a specific purpse. WARNINGS and CAUTIONS identify the hazard, indicate hw t avid the hazard and advise f the prbable cnsequence f nt aviding the hazard. PLEASE WORK SAFELY! SPECIFICATIONS: WARNINGS are safety messages that indicate a ptentially hazardus situatin, which if nt avided, can result in serius injuries r death. Rated Line Pull: 95 lbs. (7 kg) Single-line CAUTIONS are safety messages that indicate a ptentially hazardus situatins, which if nt avided, may result in minr r mderate injury. A CAUTION may als be used t alert against unsafe practice. Geartrain: -Stage Planetary MOVING PART HAZARDS TO PREVENT SERIOUS INJURY AND PROPERTY DAMAGE: D nt perate r install winch withut reading and understanding these instructins and the basic guide t winching techniques. Use supplied hk strap fr spling rpe. TAKE YOUR TIME. SLOPPY RIGGING CAUSES ACCIDENTS. Keep ther peple away. Inspect winch installatin and rpe cnditin befre perating winch. D nt use as a hist. D nt use t mve persns. D nt exceed winch's rated capacity. Never tuch rpe r hk while in tensin. Make sure the anchr yu select will withstand lad. The rpe must always spl nt the drum as indicated by the drum rtatin label n the winch. Batteries cntain gases which are flammable. Wear eye prtectin. D nt lean ver battery while making cnnectins. Failure t take prper precautin may result in fire r serius injury. Wire Rpe: 9.8',." Diameter (8 m, 8. mm Dia.) (fr D95SC) Dyneema Synthetic Rpe: 85.8',.5" Diameter (6m, 9. mm Dia.) (fr D95SRD) Fairlead: -Way Rller Fairlead (fr D95SC) Fairlead: Aluminum Hawse Fairlead (fr D95SR / D95SRD) Wireless / Wired Remte Recmmended Battery: V DC Minimum 65 CCA Battery Leads:.5 gauge, 6' (.8 m) Lng Munting Blt Pattern: " X.5" (5 mm X. mm) IP Rating: IP 67 Waterprf fr Winch Bdy Overcurrent Prtectin Perfrmance Data at Lw Speed (Gear Rati:.6:) CAUTION! TO AVOID INJURY AND PROPERTY DAMAGE! Mtr (Amps) 8.7 ft (.8 m) 85 75 (78).8 ft (. m) 95 D nt submerge the winch in water. 75 (57). ft (. m) 57 75 () 7. ft (. m) Never winch with less than 5 wraps f rpe arund the drum. 95 (7).9 ft (.5 m) 9 D nt use winch t secure a lad during transprt. Befre initiating winching peratin, be sure any elements that can interfere with safe winching are remved. Wear heavy leather glves while handling the rpe. Never wrap rpe back nt itself. Use a chker chain, tree trunk prtectr r an anchr. Cautin shuld be used if the vehicle is tied dwn during a winching peratin. This may lead t damage t the frame. D nt disengage clutch if winch is under lad r if rpe is under tensin. Drum Diameter / Length:.5" / 8.8" (6 mm X mm) Synthetic Rpe: 85.8',.5" Diameter (6 m, 9. mm Dia.) (fr D95SR) Remve all metal jewelry. Stand clear f rpe and lad during peratin. Gear Rati:.6: at Lw Speed..8: at High Speed. Brake: Aut. Lad Hlding BATTERY HAZARDS Keep hands clear f rpe, hk and fairlead pening during peratin and while spling. Mtr: V DC, 5.5HP Series Wund Clutch (freespling): Sliding Ring Gear GENERAL SAFETY PRECAUTIONS 95 LBS. WINCH Abve data are based n the first layer f drum. D nt use t tw vehicles. Befre winching, inspect remte cntrl lead fr damage. Perfrmance Data at High Speed (Gear Rati:.8:) Mtr (Amps) 7.8 ft (.6 m) 87 Abve data are based n the first layer f drum.
Layer Rated Ttal Rpe n Drum (ft/m) 95 (7) 6. ft (5 m) 77 (9) 9 ft ( m) 65 (96) 68 ft ( m) 57 (58) 95 ft (9 m) Perfrmance Data at High Speed (Gear Rati: 5.:) Mtr (Amps) 6. ft (9.6 m) 8 Layer Rated Ttal Rpe n Drum (ft/m) (555) 7.6 ft (5. m) 95 () 7 ft (. m) 79 (6) 6 ft (9. m) 677 (77) 88 ft (6.8 m) Abve data are based n the first layer f drum. LBS. WINCH SPECIFICATIONS: Rated Line Pull: lbs. (555 kg) Single-line Mtr: V DC, 6.HP Series Wund Geartrain: -Stage Planetary Gear Rati:.: at Lw Speed. 5.: at High Speed. INSTALLATION AND SETUP: SAFETY FIRST! Clutch (freespling): Sliding Ring Gear UNPACKING Brake: Aut. Lad Hlding Drum Diameter / Length:.5" / 8.8" (6 mm X mm) When unpacking, make sure that the item is intact and undamaged. If any parts are missing r brke, please call aprve authrized service center. Wire Rpe: 85.8',.7" Diameter (6 m, 9.5 mm Dia.) (fr DSC) Munting Hardware:See belw. Synthetic Rpe: 85.8',.7" Diameter (6 m, 9.5 mm Dia.) (fr DSR) Dyneema Synthetic Rpe: 85.8',.5" Diameter (6m, 9. mm Dia.) (fr DSRD) MOUNTING THE WINCH Fairlead: -Way Rller Fairlead (fr DSC) Munting using the munting frame. (Sld separately. Please cntact Aprve authrized distributrs / retailers) Fairlead: Aluminum Hawse Fairlead (fr DSR / DSRD). Select a munting site n the vehicle bumper, truck bed, bat trailer r ther suitable lcatin. Wireless / Wired Remte. Munt the fairlead t the munting frame using supplied blts, nuts and washers. Recmmended Battery: V DC Minimum 65 CCA Battery Leads:.5 gauge, 6' (.8 m) Lng ITEM Munting Blt Pattern: " X.5" (5 mm X. mm) IP Rating: IP 67 Waterprf fr Winch Bdy Overcurrent Prtectin Perfrmance Data at Lw Speed (Gear Rati:.:) Mtr (Amps).7 ft (. m) 79 (6).5 ft (.5 m) 77 6 (7) 8 ft (. m) 59 9 (86) 5.8 ft (.8 m) (58).9 ft (. m) 5 5 6 7 8 9 PN WINCH BODY MOUNTING BRACKET (OPTION) SQUARE-HEAD NUT M HEX SOCKET BOLT M X SPRING WASHER M ALU. HAWSE FAIRLEAD SPRING WASHER M HEX SOCKET BOLT M X 5 SPRING WASHER M NUT M Q TY Figure A : Alu. hawse fairlead and winch attachment t frame (fr D95SR / D95SRD / DSR / DSRD) (Prprtins and exact alignment may vary) Abve data are based n the first layer f drum.
ITEM 5 6 7 8 9 PN MOUNTING THE SOLENOID ASSEMBLY Q TY. Place the slenid bx in a suitable place near the winch t allw the cables t be ruted prperly. WINCH BODY MOUNTING BRACKET (OPTION) SQUARE-HEAD NUT M WASHER MA SPRING WASHER M HEX SOCKET BOLT M X 5 -WAY ROLLER FAIRLEAD HEX SOCKET BOLT M X 5 WASHER M SPRING WASHER M NUT M. Mark where the screw hles will be.. Verify that the installatin surface has n hidden cmpnents r structural pieces that will be damaged befre drilling.. Drill pilt hles fr the munting screws. 5. Secure in place with munting screws. Figure B : -way rller fairlead and winch attachment t frame (fr D95SC / DSC) (Prprtins and exact alignment may vary). Munt the winch t the munting frame using supplied blts and lck washers.. Place the electric winch and frame at the lcatin where it will be munted. Use the remaining hles in the munting frame as a template t mark and drill hles fr munting. 5. Verify that the installatin surface has n hidden cmpnents r structural pieces that will be damaged befre drilling. Figure D : Three pssible slenid assembly lcatins TO PREVENT SERIOUS INJURY FROM EXPLOSION DUE TO SPARKING AT THE BATTERY CONNECTION: 6. Drill the marked lcatins. Unplug the cnnectr and discnnect the battery cables befre marking ther wiring cnnectins. 7. If the prvided hardware des nt accmmdate the installatin, use SAE grade 8 blts, r higher, and trque t 5ft-lb. TO PREVENT SERIOUS INJURY FROM LEAKING BATTERY ACID: MOUNTING USING A DIFFERENT MOUNTING PLATE:. The plate must be rated t at least the winch's capacity.. Align the winch perpendicular t center line f the vehicle at the desired lcatin, and mark the lcatins f the winch base hles. Cmpare the dimensins f the marked hles t Figure C. -Ø.8. Plan a rute fr the wiring frm the pint f the vehicle where the winch will be munted, r used t the battery. This rute must be secure, ut f the way f mving parts, rad debris, r any pssibility f being damaged by peratin r maintenance f the vehicle. Fr example, yu may wish t rute the wires under the vehicle, attaching it t the frame using suitable fasteners. D nt attach the wires t the exhaust system, drive shaft, emergency brake cable, fuel line, r any ther cmpnents which may damage the wiring thrugh heat r mtin, r create a fire hazard.. If yu drill thrugh the bumper r any part f the bdy t rute the wires, be sure t install a rubber grmmet in the hle t prevent fraying f the wires at that pint. 5 5. Rute the cables frm the slenid t the battery and frm the slenid t the winch, fllwing the precautins discussed abve. See Figure E. 5 68 D nt use a dirty, crrded r leaking battery. Only use a V autmtive (r equivalent) battery, in gd cnditin. Ø6 88 Blue 557 6 Figure C : Winch dimensins, unit: mm Small Black. Befre drilling, verify that the installatin surface has n hidden cmpnents r structural pieces that will be damaged. Yellw. Drill hles apprpriate fr the hardware at the marked lcatins. 5. Install the winch using the hardware specified n the specificatin chart. 5 Figure E : Wiring cnnectins Lng Red Lng Black Shrt Red 6
. Attach the red, blue and yellw cables t the terminals n the winch. The winch terminals are clr-cded. 5. Attach the circuit breaker t the psitive terminal n the battery. LEAVE AT LEAST 5 FULL TURNS OF ROPE ON THE DRUM. 6. Attach the red battery cable t the circuit breaker. CLUTCH RELEASED 7. Attach the black battery cable directly t the negative terminal f the battery. 8. Lift the scket cver expsing the electrical switch cnnectr. Insert the cnnectr int the scket. Nte: The attachment f the mtr cables determines the directin f the cntrller's buttn. After the unit is munted and pwered, check the directin f the pwer IN and pwer OUT n the cntrller buttn. If yu wish t change the directin n the cntrller, discnnect the battery cables frm the battery, switch the mtr cable cnnectins n the mtr assembly, then recnnect the battery cables. Figure H : Clutch released 7. Hk nt the bject using a pulling pint, tw strap, tree strap, r chain. See Figure I. 9. Discnnect the cntrller when nt in use.. Overcurrent prtectin wiring. See Figure F. OVERCURRENT PROTECTION Figure I : Using a strap anchr pint RED D nt wrap the rpe arund the bject and hk nt the rpe back nt itself. BLACK This can damage the bject being pulled, and kink f fray the rpe. Figure F : Overcurrent prtectin wiring cnnectins MOUNTING ON YOUR VEHICLE 8. Attachment pint must be centered in lp f hk and the hk's safety clasp must be fully clsed. See Figure J. Please must install the winch under the fllwing tw principles, as shwn in Figure G. Knb n the right-hand side Rpe / cable shuld be bttm spled PREPARING THE ROPE. The rpe must be prperly ciled under tensin t be able t supprt a lad withut damage.. Uncil the wire rpe, except fr 5 full wraps. Figure J : Crrect and incrrect hk attachment Figure G 9. D nt use a recvery strap while winching. They are designed t stretch and can suddenly whip back twards the peratr during a winching peratin.. Place a winch damper ver the rpe span, 6 feet frm the hk t help absrb the frce released if the rpe breaks. See Figure K.. Recil the wire rpe back int the winch under at least 5 lbs. f lad. OPERATION. Examine the rpe. D nt use the winch if the rpe is frayed, kinked r damaged.. Fully charge the vehicle's battery.. Check the winch's electrical cnnectins. All cnnectins must be tight and clean.. Put the vehicle's transmissin in neutral. 5. If the vehicle where the winch is munted is nt suppsed t be mved, engage the emergency brake and blck the wheels using wheel chcks (sld separately). 6. T pull ut the rpe, mve the clutch handle t the release psitin, shwn in Figure H, slide the lp f the hk strap ver the hk, then pull n the hk strap t pull ut the rpe. 7 Figure K : Winch Damper. Re-engage the clutch by mving the clutch handle t the engaged psitin fr lw speed r high speed, shwn in Figure L. Fr yur safety, we strngly recmmend using high speed mde nly under winch recvery with n lad. 8
LOW SPEED 7. Stp the winch and release tensin n the rpe befre mving the winch damper n it. HIGH SPEED 8. D nt cntinue use f the winch until the battery is cmpletely run dwn. 9. Yu may wish t keep the engine running while using this winch, t cntinually recharge the battery. Hwever, exercise extreme cautin when wrking arund a running vehicle and ONLY perate a vehicle in an utdr area. Figure L : Clutch engaged CAUTION! D nt allw anyne t stand near the rpe, r in line with the rpe behind the winch while it is under pwer. If the rpe shuld slip r break, it can suddenly whip back twards the winch, causing a hazard fr anyne in the area. Stand well t the side while winching.. Attach the cntrller t the scket n the slenid assembly, see Figure M. D nt use the winch in a cnstant duty applicatin-it is designed fr INTERMITTENT USE ONLY. Keep the duratin f the pulling jb as shrt as pssible. If the mtr becmes very ht t the tuch, stp and let it cl dwn fr several minutes. D nt pull fr mre than 5 secnds at r near the rated lad. D nt maintain pwer t the winch if the mtr stalls. Duble line rigging will help prevent verlading and shuld be used whenever practical.. When finished pulling the lad, reverse the directin f the winch just enugh t release tensin n the rpe s that yu can unfasten the hk frm the lad and reel in the rpe. APROVE WINCH LIMITED WARRANTY STATEMENT MODEL Figure M : Cnnectin. Operate wired r wireless (tw in ne) cntrls briefly t ensure they wrk prperly, see Figure N. If peratin is reversed, the pwer cables may be cnnected backwards. Crrect any such issue befre use. OUT IN S5SC, S5SR, S5SRD, S5SC, S5SR, S5SRD, S5SC, S5SR, S5SRD, D95SC, D95SR, D95SRD, DSC, DSR, DSRD, S9SC, SSC. Aprve Prducts C., Ltd ( Seller r APROVE ) warrants t the riginal buyer that (a) the mechanical cmpnents, and (b) the electrical cmpnent f the APROVE Winch Mdel listed abve will be free f defects in material (but excludes mtr, wired rpe and fairlead) and wrkmanship fr a perid f mnths frm the riginal date f purchase. T btain any warranty service, yu must prvide APROVE with prf f purchase and date f purchase acceptable t APROVE, such as a cpy f yur purchase receipt. This warranty des nt cver the remval r reinstallatin f the winch. Aprve will, at its ptin, replace r refund the purchase price f a defective winch r cmpnent, prvided yu return the defective winch r cmpnent during the warranty perid, transprtatin charges prepaid, t APROVE Authrized Service Centers. Attach yur name, address, telephne number, a descriptin f the prblem, and a cpy f yur receipt and riginal bill f sale bearing the APROVE serial number f the defective winch and date f purchase. This warranty des nt apply (i) t finish and wire rpe and synthetic rpe, mtr, aluminum fairlead and -way rller, r (ii) if the winch has been damaged by accident, misuse, cllisin, verlading, mdificatin, misapplicatin, imprper installatin, r imprper service. This warranty is vid if any APROVE serial number has been remved r defaced. Cmmercial r industrial use r applicatin, r any histing applicatin f the winch vids the warranty. Figure N : Cntrls. When it is safe t d s, use the pwer switch n the cntrller t retract the rpe, and winch the item as desired. D nt pwer the hk all the way int the fairlead t prevent damage. 5. D nt perate the winch at extreme angles. D nt exceed the angles shwn in Figure O fr a rller fairlead. Fr a hawse fairlead, the angle shuld be as clse t straight as pssible. 5 5 THIS WARRANTY SET FORTH ABOVE IS THE ONLY WARRANTY. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY WINCH BY LAW MAY NOT BE EXCLUDED IS LIMITED IN DURATION TO MONTHS FROM THE DATE OF ORIGINAL RETAIL PURCHASE OF THE PRODUCT. 5 5 Figure O : Rller fairlead maximum winching angles 6. If the bject t be pulled must be pulled at an angle in relatin t the winch, use a pulley (sld separately) and an anchr pint directly in frnt f the winch, as shwn in Figure P, t keep the rpe pull straight. APROVE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOST PROFITS, DOWN TIME OR LOSS OF USE) UNDER ANY LEGAL THEORY, EVEN IF APROVE WAS ADVISED OF THE POSSIBLITY OF SUCH DAMAGES. Sme states d nt allw the exclusin f implied warranties r the exclusin r limitatin f liability fr incidental r cnsequential damages, r limitatins n hw lng an implied warranty lasts, s the abve limitatin r exclusin may nt apply t yu. This warranty gives yu specific legal rights. Yu may als have ther rights that vary frm state t state. APROVE reserves the right t change Prduct design withut ntice. In situatins in which APROVE has changed a Prduct design, APROVE shall have n bligatin t upgrade r therwise mdify previusly manufactured Prducts. Fr any warranty inquiries, please cntact yur lcal dealer/distributr r direct us at www.aprveatv.cm Figure P : Pulley anchring Aprve Prducts C., Ltd. TEL + 886--78 / FAX + 886--75997 N., Dadun S. Rd., Nantun Dist., Taichung 85,Taiwan inf@aprveatv.cm 9 www.aprveatv.cm