HAMRON 007059 Power Winch Instruction Manual

HAMRON 007059 Power Winch Instruction Manual

SAFETY INSTRUCTIONS

In all winching situations there is a risk of personal injury. Minimise this risk by carefully reading these instructions. Familiarise yourself with how the winch works before using it, and pay attention to safety at all times. These
instructions specify several basic rules for safe winching. It is important to use your common sense and to continuously focus on safety in all winching situations.

IMPORTANT

• Only for horizontal winching. Must not be used for vertical lifting.
• Do not exceed the maximum permitted load.

General

• Keep your hands and other parts of your body away from the wire, hook and wire guide during installation, use, and winding and unwinding.
• Be very careful when handling the wire and hook when winding and unwinding.
• Always use the supplied hook strap when unwinding and winding the wire.
• Always keen an eye on the vehicle during the winching.
• Always wear heavy-duty leather gloves to handle the wire.

Risk of fall or pinch injuries.

• The winch must not be used to lift or move persons.
• The winch must not be used to lift up, or suspend, loads.
• Never attempt to use the winch with less than five turns of the wire on the drum. The wire can release from the drum, in that the attachment of the wire to the drum is not designed to hold a load.

Risk of burn injury

• Wear heavy-duty safety gloves when handling the wire.
• Never allow the wire to slip through your hands.
• Note that the winch motor, drum and wire can get hot when the winch is in use and for some time afterwards.

Risk of burn injury.

• Remove jewellery and wear safety glasses.
• Do not lean over the battery when connecting.
• Check before drilling that there is no risk of the drill hitting a fuel line, fuel tank, brake line, or power cable etc.
• Never run power cables over sharp edges, or where they can come into contact with moving parts or near parts that get hot.
• Insulate and protect exposed wires and terminal blocks.
• Fit terminal shields according to the instructions.
• Familiarise yourself with the winch. Read through all the instructions and the guide to winching techniques so that you know how the winch works and how to use it.
• The winch must not be used by anyone under the age of 16.
• Never use the winch if you are tired or under the influence of drugs, alcohol or medication.
• Never exceed the capacity of the winch or wire as specified in the product datasheet. Reduce the load on the winch by doubling the wire with a snatch block.
• Do not use the winch or wire for towing. Safe assembly:
• Check that the anchor point can withstand the load from the winch’s maximum pulling power.
• Only use parts, components and accessories approved by the manufacturer.
• Only use parts with a strength rating of 8.8 or higher.
• Never weld retaining screws.
• Be careful when using screws longer than those supplied by the manufacturer. Long screws can damage the base plate and/or prevent the winch from being mounted safely.
• Mount the winch and fasten the hook on the end of the wire before connecting the electrical wires.
• Place the wire guide with the warning label at the top.
• Wind the wire on the drum in the direction indicated on the warning label on the winch and/or in the documentation. This is necessary for the automatic brake (if there is one) to work correctly.
• Prestretch the wire and wind it on with tension before using it. A tightly wound wire reduces the risk of seizing, which can damage the wire.
• Check the wire and hook before using the winch. A damaged, kinked or damaged wire must be immediately replaced. Replace damaged components before using the winch. Protect the parts from damage.
• Do not leave a cable-connected remote control connected to the winch when winding, rigging, or when the winch is not in use.
• Never hook the hook round the wire. This can damage the wire.
• Use a choke chain, choke cable or wooden block at the anchor point.
• Remove all objects or obstructions that can prevent the safe use of the winch.
• Take time to arrange a suitable rigging for the winching.
• Check that the anchor point can withstand the load and that the strap or chain cannot slip.
• Avoid coupling or uncoupling when the winch is loaded, when the wire is tensioned, or when the drum is moving.
• Choose an anchor point as far away as possible. This gives the winch maximum pulling power.
• Never touch a tensioned wire or loaded hook.
• Never touch the wire or hook when someone else is using the switch or when the winch is in use.
• Always stand at a safe distance from the wire and the load, and keep other persons away when winching is in progress.
• Pay attention to the stability of the vehicle when winching, and keep other persons at a safe distance. Warn persons nearby if it becomes unstable.
• Do not use the winch to secure a load.
• Keep the cable on the remote control away from the drum, the wire and the rigging. Check for cracks, pinched parts, worn cables or loose connections. Replace the remote control if it is damaged.
• If the remote control is used inside the vehicle, route the cable through a window so that it cannot get trapped in the door.
• Do not leave the remote control where it can be activated when winding, rigging, or when the winch is not in use.
• The user and other persons in the vicinity must always pay attention to the vehicle and the load.
• Always use a hook with a catch.
• Make sure the catch is closed and untensioned.
• Do not put the load on the tip of the hook or the catch. Place the load in the middle of the hook.
• Never use a hook if the opening has become bigger, or if the tip is deformed.

Avoid damaging the winch and property

• Avoid winding at an angle so that the wire is only wound up on one side of the drum. This can damage the wire, or the winch.
• Check that the coupling is always completely engaged or disengaged.
• Do not use the winch to tow other vehicles or objects. Shock loads can temporarily exceed the capacity of the wire and winch.
• Avoid unwinding the wire long distances with the winch motor. This generates heat and excessive wear on the winch motor and brake.
• Take care not to damage the vehicle chassis when winching with the wire anchored in a vehicle.
• Do not step feed a tensioned wire. Shock loads can temporarily exceed the capacity of the wire and winch.
• Do not use the winch to secure a load during transport.
• Do not immerse the winch in water or any other liquid.
• Store the remote control in a well protected, clean and dry place.
• Double the wire or use an anchor point at a long distance when rigging. This maximises the pulling power and prevents the winch being overloaded.
• If the wire has ended up in water or clay during the winching, dismantle the winch motor and rotor and dry the internal parts with hot air. Do not start the winch motor until all the parts are dry.

Wire

• Always check before use that the wire is in good condition and correctly fastened.
• Do not use the winch if the wire is damaged.
• Never replace the wire with a wire with less tensile strength.

Battery

• Check that the battery is in good condition. Avoid contact with battery acid and other contaminants.
• Always wear ANSI approved safety glasses when handling batteries.
• Keep the engine running while winching to keep the battery fully charged.
• Stand at a safe distance from the extension of the wire during the winching. If the wire comes loose or breaks, the end of the wire will be thrown back with great force.
• Keep your hands, clothing, hair and jewellery away from the winch when in use.
• Have another person keep watch and check that the winch can be used safely. Make sure that this person is at a safe distance from the vehicle and the wire before starting the winch.

Load limits.

• Never overload the winch.
• Never attempt to crank to reinforce the pulling power. This will damage the winch and can cause personal injury.

Symbols

 Read the instructions.
 Approved in accordance with the relevant EU directives.
 Recycle as electrical waste.

TECHNICAL DATA

INSTALLATION

ELECTRICAL CONNECTION

The winch can be used with temporary or permanent cable routing.

Temporary cable routing

1. Lift the rubber seal and connect the power cable to the outlet on the right side of the winch. Run the power cable from the winch to the battery. Make sure the power cable does not fasten in moving parts, or could be tripped over.

2. Connect the black clip on the cable to the vehicle chassis to make an earth connection. Connect the red clip to the positive terminal (+/red) on the battery.
   Note: Always use a 12 V vehicle battery or equivalent battery in good condition.

3. Lift the rubber seal on the left side of the winch. Lift up the remote control and connect the plug on the end of the cable to the outlet marked Remote Control on the right-hand side of the winch.

4. Put the remote control in a safe place until it is ready to be used.

Permanent cable routing

1. Connect the overcurrent protection to the positive terminal (+/red) on the battery with clamping screw on the battery terminal.
2. Plan the routing of the cables from the place on the vehicle where the winch is to be installed, or used, to the battery. The cables should be routed at a safe distance from moving parts and protected from grime. There must be no risk of damaging the cables when using or maintaining the vehicle. For example, the cables can be run under the vehicle and attached to the chassis with suitable fasteners. Do not fasten the cables to the exhaust system, drive shaft, parking brake cable, fuel line, or other components that can damage the cables, or in the worst case cause a fire as a result of heat or movement.
3. If a hole is drilled in a bumper or other part of the bodywork to route the cables, insert a rubber grommet in the hole to protect the cables from chaffing.
4. Run the power cable from where the winch is to be used to the battery. Note the same instructions as above.
5. Remove the red clip and fasten the red cable to the overcurrent protection on the positive terminal (+/red) on the battery.
6. Remove the black clip and fasten the black cable to the vehicle chassis to make a safe earth connection.

WARNING

• Always connect red to red (positive to positive) and black to the vehicle chassis to make an earth connection when the winch is run from the vehicle battery.
• The engine can be left running when using the winch to keep the battery fully charged. Pay careful attention when working near a vehicle with the engine running.
• Do not use a battery that is dirty, corroded or leaking. Risk of burn injury as a result of battery acid.
• Always wear ANSI approved safety glasses when handling batteries.

INSTALLATION

The winch is designed for temporary mounting with the bracket for the towbar. The winch can also be permanently installed.

Permanent installation

1. Choose a suitable place on the bumper or platform on the vehicle, or boat trailer, or other suitable place.
   NOTE
   This winch has a pulling power of 1570 kg. Make sure that the installation point can withstand this tension. It may be necessary to use welded steel reinforcement plates as extra support.

2. Align the winch in place and mark out drill holes through the four holes in the base plate on the winch.

3. Drill the four holes in vehicle.

4. Mount the winch with hardened steel bolts with a minimum diameter of at least 95 mm.

Temporary installation

1. Mount the three bolts in the adapter plate with the supplied nuts as shown in the diagram. Screw tight.
2. Put the bolt heads in the slots on the back of the winch.
3. Mount the unit with winch/adapter plate on the towbar by putting the ball through the hole in the adapter plate.

USE

WARNING

• Keep your hands, clothing, hair and jewellery away from the drum and wire when the winch is in use.
• Do not use the winch if the wire is damaged.
• Make sure that no one is near, or in line with the wire when it is loaded. If the wire comes loose or breaks, the end will be thrown back towards the winch with great force and could cause serious personal injury. Always stand at a safe distance to the side of the wire during the winching.

NOTE

Never use the winch or other accessories until the battery is completely discharged. This can permanently damage the battery.

1. Put the vehicle in neutral. Never use the winch with a gear engaged or in parking mode if the vehicle has an automatic gearbox. This can damage the power transmission on the vehicle.
   NOTE:
   Apply the handbrake and chock the wheels with suitable chocks so that they cannot move. Failure to do so can cause the vehicle to move during the winching and cause a very dangerous situation.

2. Pull out the wire by turning the coupling handle anticlockwise to release the wire and then pull out the required length of wire. The coupling handle can also be turned clockwise to lock the wire and then feed out the required length of wire with the remote control.
   NOTE:
   Always leave at least three turns of the wire on the drum so that the wire cannot be dragged loose from the winch.

3. Hook the object to be winched at a tow point, or with a tow line or chain. Do not wind the wire round the object and then hook the hook round the wire. This can damage the object being winched. It can also kink or chaff the wire.

4. Relock the coupling handle.

5. Stand at a safe distance and use the switch on the remote control to wind in the wire and winch the object when it is safe to do so.

PULLING POWER

1. This winch has a towing capacity of 1570 kg, which means it can be used for the following applications:
   • To move a load of up to 1570 kg from standstill on level ground.
   • To move a floating vessel of up to 4309 kg.
   • To roll a vehicle on wheels of up to 5000 kg.
2. The pulling power decreases as the gradient increases. For example the capacity to roll a vehicle of 4300 kg on level ground is reduced to 2700 kg on a gradient of 45°. See diagram below for estimated pulling power (rolling weight) on different gradients. Use pulley block and pulleys.

USING EMERGENCY CRANK

WARNING!
Do not use the crank to assist a winch that is in operation. This will damage the winch and can cause personal injury.

1. Turn the coupling handle clockwise as far as it goes by hand. Avoid forcing the handle, or pulling to hard.
2. Put the end of the hand crank over the flat part of the threaded shaft on the left side of the winch.
3. Turn the hand crank clockwise to wind up the wire. Continue until the wire is completely wound up.

MAINTENANCE

1. Lubricate the wire now and then with thin oil.
2. Lubricate the gear wheels every 6 months. First take off the coupling handle and then separate the left and right housings. Use a high quality, water resistant grease.

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