Sunrise EW3000R Electric Winch User Manual

Sunrise EW3000R Electric Winch

Product Information

Specifications

• Single line rated pull: 3000 lbs
• Gear reduction ratio: Not specified
• Motor: Permanent magnet motor
• Overall dimensions: Not specified
• Drum size: Not specified
• Cable length: Not specified
• Weight: Not specified
• Line speed and motor current (first layer):
  • Line Pull: 0 lbs, 1000 lbs, 2000 lbs
  • Line speed (FPM): 10.5, 7.5, 4.2
  • Line speed (MPM): 3.2, 2.3, 1.3

Product Usage Instructions

Installation

1. Pull and turn the clutch knob to the Off position to allow the drum to turn freely by hand.
2. Grab the cable assembly hook and pull the cable to the desired length using the handsaver bar.
3. Attach the cable to the item being pulled.
4. Ensure there are at least five turns of wire rope left on the drum before operation.

Operation

1. Engage the clutch by turning the clutch knob to the In position.
2. Insert the wire rope into the correct end of the hole provided on the drum.
3. Tighten the set screw securely.
4. Operate the winch to re-spool the wire rope around the drum.

Maintenance

1. Periodically check the tightness of mounting bolts and electrical connections.
2. Remove any dirt or corrosion accumulated on the electrical connections.
3. Do not disassemble the gearbox as it will void the warranty.
4. Repairs should be done by the manufacturer or an authorized repair centre.

FAQ

Q: What should I do if the winch motor does not operate or runs in one direction only?

A: Check for a faulty switch, broken wires, bad connections, or a defective motor. Replace or repair as necessary.

Q: How can I troubleshoot if the motor runs but the drum does not turn?

A: Ensure that the clutch is engaged. If not, engage it and try again.

Q: What should I do if the motor overheats?

A: Allow the winch to cool down periodically. If the issue persists, repair or replace the motor.

INTRODUCTION
Thank you for purchasing a 3000 Ibs winch from Sunrise. Please read and understand this Owner’s Manual before installing and using your winch.

GENERAL DESCRIPTION

Each winch is equipped with a permanent magnet motor and is designed for intermittent-duty general use. The winches are not designed to be used in industrial or hoisting applications and the manufacturer does not warrant it to be suitable for such use. The free spool Clutch is operated by a pull and turn knob which disengages the gearbox to allow the wire rope to be pulled out without using electric power. A tension plate reduces backlash and snarling when pulling out the wire rope.

GENERAL SAFETY INFORMATION

1. Never lift people or hoist loads over people. Do not lift items vertically. The winch was designed for horizontal use only.
2. DO NOT OVERLOAD. FOR LOADS OVER 1 000LBS/1250LBS/1500LBS, WE RECOMMEND THE USE OF THE OPTIONAL PULLEY BLOCK TO DOUBLE LINE THE WIRE ROPE(Figure 1)
3. Do not attempt to prolonged pulls at heavy loads. The electric winch is designed for intermittent use only. and should not be used in a constant duty application. The duration of the pulling job should be kept as short as possible. If the Winch motor becomes very hot to the touch, stop the Winch and let it cool down for several minutes. Never pull for more than one minute at or near the rated load.
4. NEVER WINCH WITH LESS THAN 5 TURNS of wire rope AROUND THE WINCH DRUM since the wire rope end fastener may NOT withstand full load.
5. AVOID CONTINUOUS PULLS FROM EXTREME ANGLES as this will cause the wire rope to pile up on one end of the drum (Figure 2) This can jam the wire rope in the winch, causing damage to the rope or the winch.
6. BE SURE THE INPUT VOLTAGE BETWEEN THE TERMINALS OF THE MOTOR IS ALWAYS DC 12V TO REACH THE MAX-RATED LINE PULL DURING THE OPERATION. PLEASE NOTE THAT IT ONLY CAN REACH THE MAX-RATED LINE PULL BY THE FIRST LAYER OF CABLE AROUND THE DRUM WHEN PULLING THE LOADS.
7. NEVER HOOK THE WIRE ROPE BACK TO ITSELF because you could damage the wire rope. Use a nylon sling. (Figure 3)
8. Be sure the winch is mounted on the vehicle or other objective before operation.
9. When moving a load, slowly take up the wire rope slack until it becomes taut. Stop, and recheck all winching connections. Be sure the hook is properly seated. If a nylon sling is used, check the attachment to the load.
10. It is a good idea to lay a heavy blanket or jacket over the wire rope near the hook end when pulling heavy loads(Figure 3). If a wire rope failure should occur. the cloth will act as a damper and help prevent the rope from whipping.
11. Do not move your vehicle to assist the winch in pulling the load. The combination of the winch and vehicle pulling together could overload the wire rope and the winch.
12. NEVER WORK ON OR AROUND THE WINCH DRUM WHEN THE WINCH IS UNDER LOAD. (KEEP AWAY THE WINCH AT LEAST 1.5M DURING THE OPERATION)
13. DO NOT CROSS OVER OR UNDER THE WIRE ROPE WHEN THE WINCH IS UNDER LOAD.
14. When using your winch to move a load, place the vehicle transmission in neutral, set the vehicle braked, and chock all wheels. The vehicle engine should be running during winch operation. If considerable winching is performed with the engine off, the battery may be too weak to restart the engine.
15. NEVER RELEASE FREE SPOOL CLUTCH WHEN THERE IS A LOAD ON THE WINCH.
16. After operation, please release the load Do not allow the cable tight any more.
17. Always stand clear of wire rope, hook and winch.
18. INSPECT WIRE ROPE AND EQUIPMENT FREQUENTLY. A FRAYED WIRE ROPE WITH BROKEN STRANDS SHOULD BE REPLACED IMMEDIATELY. USE ONLY FACTORY AP-PROVED SWITCHES, REMOTE CONTROLS AND ACCESSORIES. USE HEAVY LEATHER GLOVES WHEN HANDLING WIRE ROPE. DO NOT LET WIRE ROPE SLIDE THROUGH YOUR HANDS.
19. Keep clear of the winch, taut wire rope and hook when operating the winch. Never put your finger through the hook. If your finger should become trapped in the hook, you could lose your finger. Always use the hand-saver bar when guiding the wire rope in or out.
20. After operating the winch, re-spool the cable around the drum tightly.
21. DO NOT OPERATE WINCH WHEN UNDER THE INFLUENCE OF DRUGS, ALCOHOL OR MEDICATION. Always stay alert during the operation.
22. Use eye and ear protection. Always wear impact safety goggles. Wear a full face shield if you are producing metal filings or wood chips. Wear a dust mask or respirator when working around metal, wood, and chemical dust and mists.
23. DO NOT MACHINE OR WELD ANY PART OF THE WINCH. Such alterations may weaken the structural integrity of the winch and could void your warranty.
24. Make some maintenance frequently to the winch.

INSTALLATION

Correct installation of your winch is required for proper operation.

1. Mount the winch on the vehicle or other object using Screw M8 x30, Lock washer, Wash-er-Flat offered. Another similar screw can be instead.
   WARNING: This winch must be mounted with the wire rope in the underwind direction. Improper mounting could damage your winch and void your warranty.

2. Route the two couple of lines from the switch to the motor and battery respectively. Con-nect the red line to the positive (+) terminal and the green (or black) line to the negative(-) terminal of the 12v battery. Connect the rest two lines to the terminal on the motor of the electric winch (Figure 4)

3. Check the direction of the drum turning.
   Pull and turn the clutch knob to the “Off” position (the drum can be turned free). pull out the cable from the drum then engage the clutch by turning the knob to the “In” position. Push the “cable in” button on the handheld, if the cable is re-spooling then it is the right way to connect. Otherwise please change the line connected to the motor. And repeat the abovementioned operation.

OPERATION

1. Pull and turn the clutch knob to the “Off” position, so the drum can turn free by hand.

2. Grab the cable assembly hook and pull the cable to the desired length by the handsaver bar. Then attach it to the item being pulled.
   WARNING:
   CHECK THAT THERE ARE AT LEAST FIVE TURNS OF WIRE ROPE LEFT ON THE DRUM BEFORE OPERATION.

3. Engaged the clutch by turning the clutch knob to the “In” position.
   WARNING: CLUTCH MUST BE FULLY ENGAGED BEFORE WINCHING. NEVER ENGAGE CLUTCH KNOB WHILE DRUM IS TURNING. THE CLUTCH KNOB HAS BEEN ADJUSTED AND PERMANENTLY LOCKED IN PLACE WITH A THREAD-LOCKING COMPOUND AT THE FACTORY. DO NOT ATTEMPT TO RE-ADJUST THE KNOB.

4. Push and hold the “Cable In” button on the handheld and the cable was re-spooled. Push and hold the “Cable Out” button to reverse directions. Wait until the motor stops before reversing directions.

5. Re-spooling cable after finished operation.

MAINTENANCE

1. Periodically check the tightness of mounting bolts and electrical connections. Remove all the dirt or corrosion that may have accumulated on the electrical connections.
2. Do not attempt to disassemble the gearbox. Disassembly with void warranty. Repairs should be done manufacturer of the authorized repair centre.
3. The gearbox has been lubricated using high-temperature lithium grease at the factory. No internal lubrication is required.

REPLACE THE WIRE POPE

1. Engaged the clutch by turning the clutch knob to the “In” position.
2. When inserting the wire rope into the drum. insert it into the correct end of the hole provided. (Figure 5). Tighten the set screw securely.
3. Operate the winch and re-spool the wire rope around the drum.

CAUTION:
ALWAYS REPLACE DAMAGED WIRE ROPE WITH THE MANUFACTURER’S IDENTICAL REPLACEMENT PART.

TROUBLESHOOTING

FAULT

| POSSIBLE CAUSE|

SUGGESTED ACTION

---|---|---
The motor will not operate or run in one direction only| -Switch in operative

-Broken wires or bad connection

-Defective motor

| -Replace switch

-check for poor connections

-Replace or repair motor

The motor runs but the drum does not turn| -Clutch not engaged| -Engage clutch
The motor runs but with insufficient power or line speed| -Weak battery

-Defective motor

| -Recharge or replace battery.

-Check battery terminals for corrosion. Clean as required

-Check and clean connections

-Repair or replace motor

Motor over- heading| -Winch running time too long

-Defective motor

| -Allow the winch to cooldown periodically

-Repair or replace motor

WINCH PARTS LIST

Wiring

For the 50 amp thermal protector one side should be connected to the battery and the other side should be connected to the control box.

SPECIFICATIONS

• Single line rated pull 3000lbs(1361kg)
• Gear reduction ratio 153:1
• Motor Permanent magnet DC 12V motor with 0.85 hp output
• Overall dimensions 7.3” (L)x4.1” (W)x4.1” (H) 300(L)x105(W)x105(H)mm
• Drum size
  • ø 1.24(D)x2.88”(L)
  • ø 31.5(D)x73(L)mm
  • 30.left(L) ofø 11/51” Cable 9.2m(L) of ø5.5mm Cable
• Cable length 14.3lbs
• Weight 6.5kg

Line speed and motor current(first layer)

Line pull and cable capacity

1370
KG| 1360| 1022| 859| 722| 622
Cable capacity per layer| FT| 4.9| 11.5| 19.3| 28.5| 30.1
M| 1.5| 3.5| 5.9| 8.7| 9.2

Contact Information

• 03 9794 0415
• [email protected]
• VISIT OUR SITE
  sunriseint.com.au.

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