4X4 TOUGH 21-280467 4WD Winch User Guide

21-280467 4WD Winch

12V DC 4WD Electric Winch Warranty Details

The product is guaranteed to be free from defects in workmanship and parts for a period of 12 months from the date of purchase. Defects that occur within this warranty period, under normal use and care, will be repaired, replaced or refunded at our discretion. The benefits conferred by this warranty are in addition to all rights and remedies in respect of the product that the consumer has under the Competition and Consumer Act 2010 and similar State and Territory laws.

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Repair and Refurbished Goods or Parts Notice

Unfortunately, from time to time, faulty products are manufactured which need to be returned to the Supplier for repair.

Please be aware that if your product is capable of retaining user-generated data (such as files stored on a computer hard drive, telephone numbers stored on a mobile telephone, songs stored on a portable media player, games saved on a games console or files stored on a USB memory stick) during the process of repair, some or all of your stored data may be lost.
We recommend you save this data elsewhere prior to sending the product for repair.
You should also be aware that rather than repairing goods, we may replace them with refurbished goods of the same type or use refurbished parts in the repair process.
Please be assured though, refurbished parts or replacements are only used where they meet ALDI’s stringent quality specifications.

If at any time you feel your repair is being handled unsatisfactorily, you may escalate your complaint. Please telephone us on 1300 883104 or write to us at:

MOTOZONE AUTO ACCESSORIES
PO BOX 5213 MORDIALLOC VICTORIA 3197
Telephone: 1300 883 104
Email: sales@4x4tough.com.au

Remote Control Battery Replacement Notice

Occasionally, during shipment the battery inside the remote control may experience some power loss. For this reason, a replacement battery has been provided inside the re-sealable plastic bag. If, upon initial use of the remote control power loss is experienced, please replace the battery with the spare battery provided. Refer to Page 9. of the User Guide for detailed battery replacement instructions.

AFTER SALES SUPPORT
AUS 1300 883 104
AUS Hotline Costs: Landline calls are free. Mobile costs are extra & are dependent on carrier charges – please check charges with your mobile carrier.
sales@4x4tough.com.au,
www.4x4tough.com.au
MODEL: 21-280467 PRODUCT CODE: 705989 09/2021

Congratulations on choosing to buy a 4X4 TOUGH® product.

In the event you require assistance with your purchase please contact one of our experienced customer service tea m on 1300 883 104, who will be happy to assist with your enquiry.

Satisfied customers have repeatedly attested to the positive outcome of a simple phone call in resolving misunderstandings and gaining positive insight into product usages.
This product is manufactured to the highest standards of safety and performance and is backed by a 1 year warranty.

Please read instructions carefully before use.
Unless directions are followed physical injury or property damage may result.

Save these instructions for future reference.

Please read all instructions carefully before use. Unless directions are followed physical injury or property damage may result. Save these instructions for future reference.

Compliance
This product has been tests and meets the applicable requirements as set out by standards AS 1418.2-1997 Cranes (including hoists and winches) Serial hoists and winches.

The RCM Mark (Regulatory Compliance Mark) indicates that the product complies with the relevant guidelines of the ACMA as well as government requirements for the safety of electrical devices.

Safety Precautions

Read the following carefully before attempting to operate your winch and keep the instructions for future reference.

1. Dress Properly:

• Don’t wear loose clothing or jewelry. They can get caught in moving parts.
• Wear leather gloves when handling winch rope. Do not handle the rope with bare hands as it can cause injuries.
• Non-skid footwear is recommended.
• Protective hair covering to contain long hair..

2. Keep a Safe Distance:

• Ensure that all persons stand well clear of winch rope and load during winch operation 1.5 times the length is
  recommended. If the rope pulls loose or breaks under load it can lash back and cause serious personal injury or death.

• Don’t step over the rope.

• Draping a dampener or similar object over the extended winch rope is recommended as it will dampen any

• All onlookers should be kept away from the work area.

• Keep proper footing and balance at all times.

3. Don’t Abuse the Winch Rope:

• Never carry the winch by the rope or yank it to disconnect it from the receptacle.
• Keep cable away from heat, oil and sharp edges.

4. Don’t Overwork the Winch:

• If the motor becomes hot to touch, stop and let it cool for a minimum of 15 minutes.
• Don’t maintain power to the winch if the motor stalls..
• Don’t exceed maximum line pull ratings shown in the table. (Refer to ‘Line Pull and Cable Capacity Table’ – Page 13) hock loads must not exceed these ratings.

5. Avoid Unintentional Starting:

• To avoid accidental engagement of the winch, ensure your battery isolation switch has been activated after use;
  Refer to Installation section on Page 10 this manual.

6. Check Damaged Parts:

• Before using, check your winch carefully. Any part that is damaged should be properly repaired or replaced by an authorised service centre.

7. Repairs to the Winch

• This product should only be repaired by a suitably qualified technician using genuine parts.

8. Respool the Cable:

• Leather gloves must be worn while respooling. To respool correctly, it is necessary to keep a slight load on the rope.
• Hold the rope with one hand and the remote control switch with the other. Start as far back and in the centre as you can.Walk up keeping load on the rope as the winch is powered in.
• Do not allow the rope to slip through your hand and do not approach the winch too closely.
• Cautiously spool in the rope under power, keeping hands clear of the fairlead roller to ensure the user is not exposed to the possibility of having their hand caught.

Warning: The use of any other accessory or attachment other than those recommended in the Instruction manual may present a risk of personal injury and equipment damage.

Winch Operation Warnings

Read the following carefully before attempting to operate your winch and keep the instructions for future reference.

1.  This winch is fitted with an in-built thermal overload to prevent damage. If the winch stops during operation turn the winch off and allow it to cool before continuing.

2. The uneven spooling of rope, while pulling a load, is not a problem, unless there is a rope pile up on one section of the drum which can damage the winch. If this happens, reverse the winch to relieve the load and move your anchor point further to the centre of the vehicle. On completion of winching, unspool and rewind for a neat lay of rope on the drum; refer point 14 below.

3. Store the remote control switch inside your vehicle where it will not become damaged. Inspect it before you plug it in.

4. When ready to begin spooling in, plug in remote control switch with clutch disengaged. Do NOT engage clutch with motor running.

5. Never connect the hook back to the rope.This causes rope damage. Always use a sling or chain of suitable strength.

6. Observe your winch while standing at a safe distance. Stop the winching process every metre or so to assure the rope i s not pulling up in one corner. Jamming the rope c an break your winch.

7. Do not attach tow hooks to winch mounting apparatus. They must be attached to vehicle frame.

8. The use of a snatch block will aid recovery operations by providing a doubling of the winch capacity and a halving of the winching speed, and the means to maintain a direct line pull to the centre of the fairlead. When double loading during stationary winching, the winch hook should be attached to a rated recovery point on the vehicle.

9. Ensure rated “D” or bow shackles are used in conjunction with an approved tree trunk protector to provide a safe anch. or point. Always use shackles that comply with AS/2741 – 2002. A 4.7 Tonne shackle is recommended.

10. When extending winch rope, ensure that at least sixwraps of rope remain on drum at all times. Failure to do this could result in the rope parting from the drum under load. Serious personal injury or property damage may result

11. All winches are provided with a Red Marking on the rope to identify that 6 rope wraps remain on the winch drum.
    When this mark appears at the rollers, no recovery should be attempted beyond this marking.

12. Since the greatest pulling power is achieved on the inner most layer of your winch, it is desirable to pull off as much line as you can for heavy pulls (you must leave at least 6 wraps minimum on the drum. If this is not practical use a snatch block and double line arrangement

13. Draping a dampener or similar object over the extended winch rope is recommended as it will dampen any back lash should a failure occur

14. Neat, tight spooling avoids rope binding, which is caused when a load is applied and the rope is pinched between others. If this happens, alternatively power the winch in and out. Do not attempt to work a bound rope under load – free by hand.

15. Apply blocks to wheels of winching vehicle when vehicles are on an incline.

16. Battery:
    • Be sure that the vehicle’s battery is in good condition. Avoid contact with battery acid or other contaminants.
    • Always wear eye protection when working around a battery
    • Have the engine running when using the winch to avoid flattening the battery.
    Winch Operation Warnings

17. Be sure that the rope is in good condition and is attached properly.

18. Do not use the winch if rope is frayed.

19. Do not move the vehicle to pull a load.

20. Do not replace the rope with a rope of lesser strength.

21. The life of the rope is directly related to the use and care it receives. Following its first and subsequent uses, a  rope must be wound on to the drum under a load of at least approx. 230kg or the outer wraps will draw into the inner wraps and severely damage the rope during winching. The first winch use should be a familiarisation run while in a relaxed, non-recovery situation. Spool out the rope until the red cable mark appears (about 6 wraps on the drum), then rewind the rope on to the drum under a load of approx. 230kg or more.
    This will slightly tension and stretch the new rope and create a tight rope wrap around the drum. Failure to do so may result in rope damage and reduced rope life.

22. When the rope is replaced, be sure to apply Loctite, or an equal compound, to the rope clamp thread. Tighten the clamp screw properly but do not overtighten. The Loctite will prevent loosening of the screw in arduous conditions. Loctite 7471 Primer and 222 Threadlocker are recommended.

23. Do NOT operate and spool under full load for over one minute continuously.

24. After use, the winch will be hot. Do not submerge under water or drive through rivers or streams until the unit has cooled down. The IP67 level of waterproofing does not cover the winch when it is hot.
    IP67 relates to the level of waterproofing of the unit.
    IP67 covers the unit being submerged in water up to one metre for not more than 30 minutes.

NOTE:
The safety precautions and instructions discussed in this manual can’t cover all possible
conditions and situations that may occur. lt must be understood by the operator that common
sense and caution are factors which cannot be built into this product, but must be applied by
the operator.

Symbol Index

The following symbols appear on your winch and are IMPORTANT WARNINGS that must be adhered to.

WARNINGS

Before Installing Your Winch
Unpack: Ensure all the listed contents are included.
Read and understand the user guide prior to installing the winch on your vehicle.

12V DC 4WD Winch Parts List

4X4 Tough® 12V DC 4WD Winch Parts List

Installation

Caution: device correctly will void any warranty. The manufacturer will not be held responsible for damage caused to property or persons as a result of inadequate installation.

MOUNTING YOUR WINCH

1. a) The winch is to be mounted into a suitable steel mounting frame using the 4 point foot mounting system in either a horizontal or vertical plane.
   b) It’s very important that the winch be mounted on a flat surface so that the three sections (motor, cable drum and gear housing) are properly aligned.
   c) Before commencing installation ensure the mounting facility being used is capable of withstanding the winch’s rated capacity.
   d) The fitment of winches and / or a frontal protection system may affect the triggering of SRS air bags. Check that the mounting system has been tested and approved for winch fitment in the airbag equipped vehicle.

2. Should you wish to manufacture your own mounting plate, the dimensions below will assist. A steel mount plate 6mm thick is recommended. Fasteners should be steel high tensile grade 5 or better. A poorly designed mount may void warranty.

3. The winch should be secured to the mounting with 3/8″UNCx1-1/4″ bolts and spring washers provided.

4. The roller fairlead is to be mounted so as to guide the rope onto the drum evenly.

LUBRICATION INFORMATION
All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly.
Under normal conditions factory lubrication will suffice. If the rope cable becomes worn or damaged it must be replaced.

ROPE INSTALLATION
It is recommended that if the synthetic rope needs to be replaced you engage a qualified technician to perform this task.

AUXILIARY ITEMS (not included)
As a further safeguard, you may wish to consider installing the following items:

• An additional isolation switch on the positive lead from your battery to avoid the possibility of malicious use by an ill intentioned person.
• A second battery to avoid depleting the power of the battery that starts your vehicle, as the use of any winch draws a considerable amount of power.

ELECTRICAL CONNECTION

For normal self-recovery work, your existing electrical system is adequate. A fully charged battery and proper connections are essential. Run the vehicle engine during winching operations to keep battery charged.
Pay close attention to proper electrical cable connection as follows (refer to diagrams below):

1. Short red cable (A) with red jacket connecting to the red terminal (A) of the motor.
2. Short black cable with yellow jacket (B) connecting to the yellow terminal (B) of the motor.
3. Short black cable with blue jacket (C) connecting to the blue terminal (C) of the motor.
4. Thin black cable (Earth) connecting to bottom Earth Terminal of the motor.
5. Long black cable (1.8m one terminal connecting to the bottom Earth Terminal of the motor, and the other terminal connecting to negative (-) terminal of the battery.
6. Long red cable positive (+) connecting to positive (+) terminal of the battery.
7. It is essential that the cables are correctly connected by an experienced person who understands the wiring connection procedure. Incorrect wiring may cause the solenoid unit to cease operating. In such cases new solenoid replacements are available for purchase.

CAUTION:

1. Your battery must be kept in good condition.
2. Be sure battery cables are not drawn taught across any surfaces which could possibly damage them.
3. Corrosion on electrical connections will reduce performance or may cause a short.
4. Clean all connections especially in remote control switch and receptacle.
5. In salty environments use a silicone sealer to protect from corrosion.
6. Check electrical cables and connections after each use.

Winch Operation

SUGGESTION:
The best way to get acquainted with how your winch operates is to make a few test runs before you actually need to use it. Plan your test in advance. Remember you can hear your winch as well as you can see it operate. Get to recognise the sound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Soon you will gain confidence in operating your winch and its use will become second nature to you.

OPERATING:

1. Ensure the vehicle is secure by applying the parking brake or chocking the wheels.

2. Pull out the winch rope to the desired length and connect to an ancho r point. A suggestion would be a tree trunk protector wrapped around a suitably sized tree which will not be damaged by the winching operation.
   The winch clutch allows rapid uncoiling of the rope for hooking onto the load or anchor point. The shifter tab located on the gear housing of the winch operates the clutch as follows: a) To disengage the clutch, move the clutch shifter tab to the DISENGAGE position. Rope may now be free spooled off the drum..
   b) To engage the clutch, move the clutch shifter tab into the ENGAGE .position. The winch is now ready for pulling.

3. Re-check all rope rigging before proceeding.

4. Plug in the winch remote hand control (see Page 10 for instructions). It is recommended that the winching operation takes place from the driver’s position to ensure safe operation.If using the wireless remote control always ensure that you are located at a distance which is greater than 1.5 times the length of the exposed cable.

5. Turn the winch on by turning the on / off orange switch to the on position (clockwise)

6.  To commence winching operation, start vehicle engine, select neutral in transmission and maintain engine speed at idle.

7. Operate the remote control switch to IN or OUT until the vehicle has been retrieved. Stop the winch regularly to ensure that the rope is winding onto the drum evenly.

CAUTION:

• Check the winch carefully and thoroughly before operating.
• Never winch with your vehicle in gear or in park. This would damage your v ehicle’s transmission.
• Never wrap the rope around the object and hook onto the rope itself. This can cause damage to the object being pulled, and kink or fray the rope.
• Keep hands, clothing, hair and jewellery clear of the drum area and rope when winching.
• Never use the winch if the rope is frayed, kinked or damaged.
• Never allow anyone to stand near the rope, or in line with the rope while it is under load. If the rope should slip or brake, it can suddenly whip back along the line of pull, causing a hazard for anyone in the area. Always stand well to the side while winding.
• ALWAYS disengage the winch when not in use.

5443 kg /12,000 lb Line Pull and Cable Capacity Table

Maintenance & Storage

It is highly recommended that the winch be used regularly (once a month). Simply power the rope out 15m, free spool 5 m and then power back in. This will keep all components in good working condition.

All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly. Under normal conditions factory lubrication will suffice. Inspect for any frays in the rope and replace if necessary. If the rope becomes worn or damaged it must be replaced.

If you choose to remove the winch from your vehicle, store in an ambient, dry environment until you are ready to re-install

CAUTION:

1. Your battery must be kept in good condition.
2. Be sure battery cables are not drawn taught across any surfaces which could possibly damage them.
3. Corrosion on electrical connections will reduce performance or may cause a short.
4. Clean all connections especially in remote control switch and receptacle.
5. In salty environments use a silicone sealer to protect from corrosion.

It is also recommended to have your winch serviced every 12 months to keep the unit in optimum working condition. Your 4X4 Tough winch should only be serviced by qualified persons. Examples include, qualified mechanics, auto electricians and engineers. The winch should be removed from the vehicle prior to beginning the service. Please ensure geniune parts are used for any spare parts that may be required during the service.

Contact the customer service department on 1300 883 104 if necessary to obtain parts under warranty. Photographs of faulty parts are recommended to support warranty claims.
Please email these to sales@4x4tough.com.au

Disposal

• Please consider when disposing of electronic products such as a winch that some components can be recycled and recovered for re-use. Do not attempt to dissemble any electronic product unless you are a trained electronics technician.
• Many councils hold e-waste (electronic waste) collections. Contact your nearest council to enquire about the best method of disposal in your area.

FAQ

Q: How much rated line pull do I need?
A: Rated line pull refers to the maximum amount of weight that a winch can shoulder, so you need a winch with enough strength to handle your vehicle’s weight. Thankfully, there is a simple formula for calculating the correct rated line pull: Gross Vehicle Weight x 1.5 = Minimum Rated Line Pull.

Q: Can I remove my winch?
A: Yes. During the off season, you can unbolt your winch and leave it at home. Some mounts make it easy to remove the winch, and some require a bit more effort. Hitch mounts and grille guard mounts are the easiest since the winch is so accessible. In a hidden, semi-hidden or replacement bumper setup, the winch sits behind or below the bumper, so removal can be tricky.

Q: Can I operate my winch wirelessly?
A: Yes. While all winches come with a wired remote control, your 4X4 Tough Winch also operates wirelessly. With maximum ranges of between 25 and 30 metres, Refer to the operating instructions on page 13 within this manual.

Q: What’s the difference between electric and hydraulic winches?
A: The basic difference between an electric and a hydraulic winch is the power source. Electric winches link to the vehicles battery, whereas hydraulic winches are driven from the power steering pump. Electric winches are the most prevalent in the market place and as such greater choice is available. They have the advantage of being able to operate without the vehicle running, however as they draw significant power from the battery it is recommended the vehicle be running whilst winching operations are underway .Electric winches generate significant heat and it is important they be run for only short periods of time before being rested to cool down. Hydraulic winches are able to operate on a more continuous basis, however they can only operate if the vehicle is running.

TROUBLESHOOTING

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