WINCHMAX 10000lb Military Grade 12v Electric Winch Instruction Manual

: June 1, 2024
: WINCHMAX

Table of Contents

WINCHMAX 10000lb Military Grade 12v Electric Winch Instruction Manual
2. PHYSICAL INSTALLATION
3. ELECTRICAL AND HYDRAULIC CONNECTION SCHEMATIC
4. SPOOLING THE ROPE
5. WINCH OPERATION
6. MAINTAINING YOUR WINCH
7. WIRE ROPE
8. SYNTHETIC ROPE
Troubleshooting
Technical Data 10,000lb Hydraulic Winch
Specifications 15,000lb Hydraulic Winch
Technical Data 15,000lb Hydraulic Winch
- References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

WINCHMAX 10000lb Military Grade 12v Electric Winch Instruction Manual

WINCHMAX 10000lb Military Grade 12v Electric Winch.jpg

10,000lb (4,535kg) 15,000lb (6,803kg) & 20,000lb (9,071kg)

VERY IMPORTANT – YOU MUST READ AND UNDERSTAND THIS GUIDE BEFORE INSTALLING AND OPERATING YOUR WINCH

WINCHMAX LTD
WWW.WINCHMAX.CO.UK

Thank you for buying a WINCHMAX brand winch. By using this product within its limitations and following the instructions provided you can expect many years of trouble-free service.

IMPORTANT
PLEASE READ AND UNDERSTAND THIS ENTIRE MANUAL BEFORE INSTALLING OR OPERATING THIS PRODUCT – FAILURE TO DO SO COULD RESULT IN DAMAGE TO PROPERTY, SERIOUS INJURY OR DEATH. UNDERTAKE A FULL SAFETY CHECK AND RISK ASSESSMENT BEFORE EACH USE.

Whilst we have attempted to provide comprehensive guidance for the safe operation of this winch, it remains the operator’s responsibility to evaluate and minimise the potential risk before and during every operation. Keep these instructions for reference.

1. WARNINGS AND GENERAL SAFETY INFORMATION

To prevent entanglement in moving parts, no loose clothing or jewellery should be worn.
Good quality overalls, non-slip protective footwear, thick leather gloves and eye protection should be worn.
It is the operator’s responsibility to ensure he/she and all spectators remain at a safe distance. For spectators, this should be at least 1.5 times the rope length being used.
Check your winch thoroughly, including all hydraulic and electrical connections before use. Any damaged parts should be replaced, using only genuine parts.
Protect the winch from shock loads – do not allow the winch rope to be yanked by a rolling load or moving vehicle. Never drive your vehicle to assist the winch in any way.
If a wire rope breaks or pulls loose under load it can lash back with significant force.
With wire rope, it is a good idea to use a heavy winch blanket/damper draped over the rope towards the hook end to reduce whiplash in the event of rope failure. The vehicle bonnet can be raised to provide additional protection when operating from inside the vehicle.
Do not use the winch if the rope is frayed or damaged.
Never handle the hook directly. Always use the hand-saver tab and protective gloves.
Never hook the winch rope back on itself as this can damage the rope.
Always electrically isolate the control system when not in use to protect against unintended operation.
Do not use the winch as a hoist or for overhead lifting.
Do not use the winch to lift, support or move personnel.
Always ensure the winch rope re-spools tightly and evenly on to the drum. Do not allow cable bunching as this could damage the crossbars and winch casing.
Never approach the winch, hook, or cable if someone else is at the controls.
Always be certain the anchor point can withstand the load and will not slip or fail.
Protect the wireless (optional) remote from any possibility of accidental operation.
Never apply load to a wire rope if it is kinked as doing so will deform or fracture the wire strands and cause permanent damage.

2. PHYSICAL INSTALLATION

WARNING: correct installation of your winch is vital for correct and safe operation.

Only install your winch with a genuine WINCHMAX mounting plate or bumper. For these instructions, we are describing installation using a pre-drilled WINCHMAX mounting plate suitable for flatbed installations.
The winch must be mounted with the direction of pull perpendicular to the mounting bolt fixings and the mounting point on the vehicle must be capable of withstanding the maximum rated pull of the winch.
Mount the fairlead (rollers if the winch is fitted with steel wire rope, or aluminium hawse if the winch is fitted with un-sheathed synthetic rope) to the upstand of the mounting plate using supplied bolts, nuts and washers.
Mount the winch to the mounting plate using supplied bolts, square nuts and washers, tighten the mounting bolts to a torque of 60Nm (45ft/lb). All mounting
points should be utilised.
The supplied bolts are the correct length for installation on a 5-7mm plate. Other thickness’s may require bolts of a different length. The required criteria are that the bolts are at least 8.8 grade high tensile, the thread length should be sufficiently long to fully engage the square nut but must not protrude to the extent that the bolt contacts the top of the nut housing in the winch frame.
Feed the hook end of the wire rope from the drum through rollers to the front and attach the clevis hook. Where the thimble eye is too big or if a fixed hook is used, you may need to remove the top fairlead roller to allow the hook end to pass through.
With a synthetic rope with a spliced-on hook you may need to pull the rope off and feed the rope back through the hawse fairlead from the drum end.

FIG 1 PHYSICAL INSTALLATION.JPG

3. ELECTRICAL AND HYDRAULIC CONNECTION SCHEMATIC

FIG 2 ELECTRICAL AND HYDRAULIC CONNECTION
SCHEMATIC.JPG

WARNING: THE HYDRAULIC SUPPLY MUST BE FITTED WITH A SUITABLE REGULATOR.
DO NOT EXCEED THE RATED PRESSURE OF 108 BAR (1500 PSI).

The connection and set up of the hydraulic supply should only be undertaken by a hydraulic engineer or suitably competent person.
The specification of the hydraulic supply is critical – it must not exceed the limitations of pressure or flow as to do so could cause catastrophic failure of the winch.
Where the hydraulic pump can exceed the maximum working pressure of the winch a suitable pressure regulator must be installed and calibrated to protect the winch from over-pressure.

Remote Control (non-wireless).
The primary remote control for your winch is the plug-in wander lead. This should be connected as per the schematic (Fig A).

Please ensure that the electrical supply from the battery(s) matches the coil voltage (12v / 24v) of the solenoid direction valve. Where the vehicle has a 24v system consisting of two 12v batteries wired in series, a 12v supply can be derived from a single battery If required.
Drill a suitable hole in the vehicle sheet metal or make a bracket and install the socket in a secure location beside the control valve.
Connect one of the two pairs of 300mm wires to the coils on each side of the directional control valve (it does not matter which way around the red and black wires are connected).
Connect the two 3m battery leads (red) to the positive and (black) to the negative terminals of the vehicle battery(s).

Remote control (wireless)

Mount the control box in a suitable location beside the control valve.
For the initial set-up of the winch, the wander lead should be used.
Connect one of the two pairs of 300mm wires to the coils on each side of the directional control valve (it does not matter which way around the red and black wires are connected).
Take care when inserting the wireless remote plug into the control box socket, you must line up the socket end with the groove in the socket.
The controls can now be used in the wireless mode or connected to the control box using the lead provided for manual back-up and fine adjustments (for example when the load is close to the winch).

4. SPOOLING THE ROPE

We recommend the use of an assistant when spooling the rope.
Spooling should be undertaken on a large open and level area.
First, lay out the rope in front of the vehicle ensuring there are no twists or kinks.
With the winch clutch disengaged, feed the drum terminal through the front of the roller/ hawse fairlead and connect to the drum.
a) If the winch has a ‘through the drum’ type fixing, undo the Allen head grub screw and feed the end of the rope through the hole until it is visible on the other side. Secure the grub screw.
b) If the winch has a ‘flange’ type fixing then secure the ring terminal at the end of the rope using the Allen head cap screw, but only tighten finger tight to allow the fixing to swivel on the screw.
Attach the hook end to a suitable anchor point and position the vehicle so there is at least 3m of slack on the rope. Apply the vehicle hand brake.
Holding the rope with gloved hands and at least 5m back from the winch apply as much pressure as you can by leaning your body weight against the rope and walking towards the winch whilst using the wired remote to wind in. Ensure that each wrap lays tightly next to the other until the rope tensions against the anchor point. There should be at least 6 wraps around the drum.
The rope must be wound onto the drum from the bottom of the drum.
Using the wired remote and whilst gently applying the vehicle foot brake to maintain tension, use the winch to pull the vehicle towards the anchor point.
During the operation, regularly stop the winch, apply the handbrake to maintain tension and check the rope is evenly spooling onto the winch.
If you have an assistant, they should remain in the vehicle to operate the brake, whilst you maintain control of the winch from outside the vehicle using the wired remote.
When the rope is all but approx. 3m spooled in, using the hand saver to hold the hook, reverse the winch slightly to allow the hook to be released.
Maintaining tension on the rope, pulse the remote to take in the remaining rope and then anchor the hook onto a suitable mounting point on the vehicle.

Note

Important: it is the first 6-8 tight wraps around the drum and NOT the drum terminal fixing point that allows the wire or synthetic rope to grip onto the drum.
The drum fixing is not load-bearing. It is only designed to allow the cable to be wound on under sufficient load for it to wrap tightly onto the drum.
When wire rope is new it is greasy and springy and can easily unwind on the drum if tension is ever released.
If the outer wraps of a wire rope do ‘unwind’ then you must pull the whole rope out and re-spool under tension. Failure to observe this will result in failure of the drum fixing.

5. WINCH OPERATION

Ensure vehicle is secure by applying parking brake or chocking wheels.
The gearbox handle has two positions ‘engaged’ and ‘disengaged’. For free spool the gearbox should be disengaged. For power operation, the gearbox must be fully ‘engaged’.
Power out (for a short distance) or free-spool the cable out and connect the hook to a suitable anchor point.
Re-check all cable rigging before commencing.
Plug in the winch hand controller. Feed the hand controller around the front of the vehicle and through the driver’s window.
Operate the winch whilst guiding the path of the winch with the vehicle steering as necessary.
You must ensure that the cable winds evenly onto the drum. Acute angle winching can result in rope bunching on the drum and excessive lateral loading resulting in damage to the drum flanges and cross-bars.
When the operation has been completed inspect the rope, if it has not spooled tightly and evenly it should be pulled out and re-spooled correctly under tension for next use.
Do not exceed the maximum rated load of your winch.
We recommend the use of a snatch block and double line technique for any loads exceeding 50% of winch rating. Always anchor hook back to suitable chassis fixing, not the winch mounting plate.
A minimum of 6-8 tight wraps on the drum must be maintained to prevent failure of drum fixing. Do not pull wire rope out past the red marking.
The clutch must be fully engaged for any powered winching operation. Do not attempt to disengage the clutch under load.
Do not attempt to re-engage clutch while the winch is running.
Never use vehicle traction to assist the winch in any way.
It must be understood that the fairlead acts as a guide only, it is not designed to withstand winch loads. It must not be used to change the direction of the rope any more than a few degrees in the vertical or horizontal plane.
If you need to change the direction of pull to a greater degree, then a suitable snatch block or pulley must be used.

6. MAINTAINING YOUR WINCH

The winch should be operated at least once a month: power out approx. 10m of cable, free spool 5m, then power back in under minimum 100kg load.
Regularly check all fixing bolts and the crossbar fixings are secure.
All moving parts are permanently lubricated with grease and with normal use do not need greasing for the life of the winch.
Clean your winch after use, use only low-pressure water and a brush to rinse off any dirt.
Once dry you should use a light spray oil to coat the winch and wire rope before installing the winch cover.
The winch should not be immersed in dirty water.
Replace any damaged components before next use.

7. WIRE ROPE

Wire Ropes Directive ISO 4309:2004/2010 details the guideline for the care and maintenance of wire rope and provides the criteria by which rope should be replaced.
A summary of these follow below.

10 strands or more broken within a 25mm length of the rope.
Visible signs of stretching (reduced diameter along part of length) or is 10% less than its original diameter at any point along its length.
Excessive corrosion.
Deformed twisted, kinked or bent.
Faulty or broken hook or hook safety catch.
Never use the hook to link back to the rope.
Always ensure that the rope spools tightly and neatly back onto the drum.
Lubricate the rope and hook with light oil to inhibit corrosion.
Keep the winch covered when not in use.

8. SYNTHETIC ROPE

Do not allow the rope to contact sharp or abrasive objects.
Avoid immersion in dirty water.
Do not expose to strong detergents, fuels, oils or anti-freeze solutions.
Avoid contact with high temperature surfaces e.g. exhaust/engine.
After use, pull out the rope, wash, dry and carefully re-spool onto the drum.
The first 2-3m from the hook end is the most exposed and so vulnerable to damage.
The use of a protective rope protector is recommended.
Keep winch covered when not in use.
Replace rope if there is any significant fibre damage.

Troubleshooting

FIG 3 Troubleshooting.JPG

FIG 4 Troubleshooting.JPG

Warranty
For warranty information and registration please visit www.winchmax.co.uk /warranty-registration or scan the QR code shown here.

CERTIFICATE of Conformity

Applicant: WINCHMAX LTD
Address: BUNGAY, SUFFOLK, NR352AN, ENGLAND, UK
Product: HYDRAULIC WINCH
Voltage: 12/24 volt control systems
Models: WM10000, WM15000, WM20000

The tests were performed in normal operation mode. The test results apply only to the particular sample tested and to the specific tests carried out. This certificate applies specifically to the sample investigated in our test reference number only.

The CE markings as shown below can be affixed on the product after preparation of necessary technical documentation.

FIG 6.JPG