Detail K2 S9500HS Use and Care Manual
Contents
1. Motor does not turn on Switch Assembly not connected properly Loose battery cable connections Defective Switch Assembly Defective motor Water has entered motor Insert Switch Assembly all the way into the connector Tighten nuts on all cable connections Replace Switch Assembly Check for voltage at armature port with Switch pressed If voltage is present replace motor Allow to drain and dry Run in short bursts without load until completely dry Motor runs but cable drum does not turn Clutch not engaged Turn clutch to the In position If problem persists a qualified technician needs to check and repair Motor runs slowly or without normal power Insufficient current or voltage Battery weak recharge Run winch with vehicle motor running Loose or corroded battery cable connections Clean tighten or replace Motor overheating Winch running time too long Allow winch to cool down periodically Motor runs in one direction only Defective Switch Assembly Loose or corroded battery cable or motor cable connections Clean and tighten Repair or replace switch assembly 12 Winch Assembly Drawing INCH ASSEMBLY DRAWING prototype ww 77 8 u MMDD E 3 4 JE J i gt g mls gt 1 Mg o S2. Use only manufacturers identical replacement rope with the exact specifications Inspect the winch installation and bolts to ensure that all bolts are tight before each operation Never connect the cable back to itself This will cause cable damage Always use a snatch block sling or chain of suitable strength as shown in the illustrations Store the remote control inside your vehicle in a place that it will not be damaged Any winch that appears to be damaged in any way is found to be worn or operates abnormally SHALL BE REMOVED FROM SERVICE UNTIL REPAIRED It is recommended that the necessary repairs be made by a manufacturer s authorized repair facility Pull only on areas of the vehicle as specified by the vehicle manufacturer Only attachments and or adapters supplied by the manufacturer shall be used RIGGING TECHNIQUES Self Recovery Locate a suitable anchor such as a strong tree trunk or boulder Always use a sling as an anchor point AA4CAUTION Do not attach the clevis hook back onto the cable as this could cause damage to the cable As shown in Fig 3 1 R a Do not winch from an acute angle as the wire rope will pile up k Sie i a on one side of the drum causing damage to wire rope and the TJ T winch Fig 3 2 MEJ wrong Short pulls from an angle can be used to straighten the vehicle Long pulls should be done with the wire rope at a 90 angle to the winch vehicle i i il Right Fig 3 2 When
3. Electric winches are designed and made of intermittent use and should not be used in constant duty applications 7 ANCAUTION Never release the free spool clutch when there is a load on the winch AMCAUTION Use hand saver hook when handling the hook for spooling or un spooling the wire rope GENERAL TIPS FOR SAFE OPERATION The 9500lbs and its all derivative types are rated at 9500 Ibs capacity when spooling the first rope layer on the drum Overloads can damage the winch motor or wire rope For loads over 8000 lbs we recommend the use of the pulley block snatch block to double the wire rope line The will aid in two ways a reduce the number or rope layers on the drum as well as b reduce the load on the wire rope by as much as 50 When doubling the line back to the vehicle attach to the frame or other load bearing part The vehicle engine should be kept running during operation of the winch to minimize battery drain and maximize power and speed of the winch If the winch is used for a considerable time with the engine off the battery may be drained and too weak to restart the engine Get to know your winch before you actually need to use it We recommend that you set up a few test runs to familiarize yourself with rigging techniques the sounds your winch makes under various loads the way the cable spools on the drum etc Inspect the wire rope and equipment before each use A frayed or damaged rope shall be replaced immediately
4. are at least 5 wraps of wire rope around the winch drum m Drape a blanket or jacket over the wire rope approximately 5 to 6 feet from the hook Open the hood for added protection n Clear the area Make sure all spectators all well back and that no one is directly in front or behind the vehicle or anchor point o Begin winching Be sure that the wire rope is winding evenly and tightly around the drum The vehicle that is being winched can be slowly driven to add assistance to the winching process Avoid shock loads keep the wire rope under tension p The vehicle to be winched should be placed in neutral and the emergency brake released Only release the brake pedal when under full tension Avoid shock loads to the winch This can damage the winch rope and vehicle q The winch is meant for intermittent use Under full load with a single line rig do not power in for more than a minute without letting the motor cool down for a few minutes and then resume the winching operation r The winching operation is complete once the vehicle is on stable ground and is able to drive under its own power s Secure the vehicle Be sure to set the brakes and place the vehicle in park 10 t Release the tension on the wire rope The winch is not meant to hold the vehicle for long periods of time u Disconnect the wire rope from the anchor v Rewind the wire rope Make sure that any wire already on the drum has spooled tightly and neatly If not
5. feeds onto the drum in the under wind position through the roller fairlead and is looped at the end to accept the clevis hook pin Roller Fairlead When using the winch at an angle the roller fairlead acts to guide the wire rope onto the drum and minimizes damage to the wire rope from abrasion on the winch mount or bumper Mechanic Gear System The reduction gears convert the winch motor power into extreme pulling forces Braking System Braking action is automatically applied to the winch drum when the winch motor is stopped and there is a load on the wire rope The braking action is applied by a separate mechanical brake Free Spooling Clutch The clutch allows the operator to manually disengage Out the spooling drum from the gear train free spool Engaging the clutch In locks the winch into the gear system Solenoid Power from the vehicle battery flows through the weather sealed switch before being directed to the winch motor Remote Switch The Power switch lead has a dual switch for powering in or powering out your winch drum The Power switch leads allow you to stand clear of the wire rope when the winch is under load 10 Wireless Remote Control allow you control winch far from 50 Ft away 3 11 Universal Flat Bed Mounting Channel Your winch has been optional supplied with a flat bed mounting channel that can be mounted to most flat surfaces such as trailers step bumpers t
6. pulling a heavy load place a blanket or jacket over the wire rope five or six feet from the hook In the event of a broken cable it will dampen the snap back For additional protection open the hood of the vehicle as shown in Fig 3 3 For pulls over 8000lbs we recommend the use of the snatch block pulley block to double line the wire rope Fig 3 4 This reduces the load on the winch and the strain on the rope by approximately 50 Single Line Double Line Fig 3 4 AN WARNING Never use your winch for overhead hoisting or for lifting people or moving people INCHING TECHNIQUES A Z a Take time to asses your situation and plan your pull b Put on gloves to protect your hands c Disengage the clutch to allow free spooling and also save battery power d Attach the hand saver hook to the clevis hook e Pull out the wire rope to your desired anchor point using the hand saver hook f Secure the clevis hook to the anchor point Sling chain or snatch block Do not attach the hook back onto the wire rope g Engage the clutch h Connect the remote control to the winch i Start your engine to ensure power is being replenished to the battery j Power in the wire rope guiding the wire under tension to draw up the slack in the wire Once the wire is under tension stand well clear Never step over the wire rope k Double check your anchors and make sure all connections are secure Inspect the wire rope Make sure there
7. 5RS 1 Remote Control Switch R2 By Choice 37 95RS 1 Remote Control Switch R3 No Choice 38 950800 1 Cable Assembly Optional Not Enclosed 39 950900 1 Roller Fairlead 40 951000 1 Mounting Channel By Choice 40 1 Speed Mount Hitch Adapter By Choice 41 951100 1 Tensioner Of Steel Wire Supplied Assembly 42 951200 1 Snatch Block Pulley Rated line pulls 9500 Ibs 42 23kN Gear reduction ratio 110 1 12V 24V Motor Series Wound Input Power 8 6 hp 6 4kW DC 12V 10 7hp 8 0kW DC 24V Overall dimensions 22 8 L x6 3 W x9 6 H 579 L mm X 160 W mm X 245 H mm Drum size 02 48 D x 8 8 L 63 D mm x224 L mm Cable 3 8 D x 85 L 9 2mm D x 26m L Weight 69 7lbs 31 6 kgs 70 5lbs 32kgs S TYPE DUTY CYCLE Line speed and motor current First layer Line speed Motor current EPS PRN ft min m min Amps Max lbs KN 12V DC 24V DC 12V DC 24V DC 0 80 2 16 3 53 15 16 2 80 45 4000 17 78 17 06 5 2 18 37 5 6 300 175 6000 26 67 11 81 3 6 15 75 4 8 400 230 8000 35 56 9 51 2 9 13 12 4 0 470 300 9500 42 23 8 86 2 7 11 81 4362 530 335 Line pull and cable capacity Rated line pull per Layer Cable capacity per Layer Layer of cable ibs kN y f y 1 9500 42 23 15 1 4 6 2 7600 33 78 34 1 10 4 3 6200 27 56 57 7 617 60 4 5400 24 00 83 7 25 5 WARRANTY Your Power Equipment wi
8. ELECTRICAL WINCH 9500HS Assembly amp Operating Instructions INTRODUCTION Congratulations on your purchase of a winch We design and build winches to strict specifications and with proper use and maintenance should bring you years of satisfying service WARNING Read study and follow all instructions before operating this device Failure to heed these instructions may result in personal injury and or property damage Your winch can develop tremendous pulling forces and if used unsafely or improperly could result in property damage serious injury or death Throughout this manual you will find the following symbols for caution warning and danger Pay particular attention to the notes preceded by these symbols as they are written for your safety Ultimately safe operation of this device rests with you the operator Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This notation is also used to alert against unsafe practices CAUTION A WARNING could result in death or serious injury Indicates a potentially hazardous situation which if not avoided INCLUDED WITH YOUR WINCH DESCRIPTION 1 Cap Screw M10 X 35 Lock Washer 10 9 NOT RO D Winch Assembly with Wire Rope Thinck Flat Washer 010 Hex Flange Nut M10 Clevis Hook w Pin Control box of 9500 Supplied for Prototype Control box of 9500 S Supplied for S Type Power Switch supplied by
9. Sela zol E mego gt Z xix od S JT A i rite Sle Re 2 gt 8 i 8 o IM T Ni J HA ATA wus Z wd 6 13 INCH PARTS LIST Prototype No Part Qty Description Remark 1 950001 1 Terminal Protect 2 950100 1 Motor Assembly 3 950002 6 Cap Screw M10 x 35 4 950003 6 Lock Washer 010 5 950004 6 Think Flat Washer 010 6 950005 6 HeX Flange Nut M10 7 950200 1 Break Shaft Assembly 8 950006 2 Bushing Drum 9 950007 2 Tie Bar 10 950008 1 Cap Screw M6 x 10 11 950009 4 Think Flat Washer 8 13 950300 1 Drum Assembly 14 950011 10 Screw M4 x 25 15 950012 10 Lock Washer 04 16 950013 1 End Bearing 17 950014 1 Gasket 18 950015 1 Gear Ring 19 950400 1 Gear Carrier Assembly Input 20 950500 1 Gear Carrier Assembly Intermediate 21 950016 1 Trust Washer 22 950600 1 Gear Carrier Assembly Output 23 950017 1 Gear Input Sun 24 950018 1 Trust Washer 25 950019 1 Gear Housing 26 950020 1 Clutch Screw 27 950021 1 Ring Seals 28 950022 1 Clutch Cover 29 950023 1 Clutch 30 950700 1 Control Box 31 950024 2 Screw M5 x 10 32 950025 2 Lock Washer 05 33 95WRR 1 Wireless Remote Control Receiver By Choice 34 95WRS 1 Wireless Remote Control Switch By Choice 36 95RS 1 Remote Control Switch R1 By Choice 36 9
10. d from inside the channel This will allow enough clearance for the winch to be placed in the channel without obstruction 3 Assemble the winch to the Mounting Channel Part 951000 by first pulling and releasing the clutch knob to Off position Free Spooling Pull out a few inches of cable from the drum and feed the wire loop through the opening in the front of the mounting channel and roller fairlead Now using the remaining M10 x 35 Cap Screws Part 950002 Flat Washer Part 950004 Lock Washer Part 950003 and Nut M10 Part 950005 secure the winch to the mounting channel 4 Connect the battery and motor leads as the drawing above every type of winch is different each other AM CAUTION Batteries contain gases which are flammable and explosive Wear eye protection during installation and remove all jewelry Do not lean over battery while making connections 5 Assemble the Clevis Hook to the cable Take off the pin from the Clevis Hook connect the Clevis Hook to the cable and mount the pin back to the Clevis Hook 6 Always use the Hand Saver when free spooling and re spooling the wire rope Using the Hand Saver keeps your hands and fingers away from the rotating drum 7 Check for proper drum rotation Pull and turn the clutch knob to the off position Free spooling Pull out some cable from the drum and then turn the clutch knob to the In position to engage the gears Press the cable out button on the pow
11. draw out the wire and re spool from the point where the rope is tight w Keep your hands clear of the winch drum and fairlead as the wire rope is being drawn in x Secure the hook and hook strap y Disconnect the remote control and store in a clean dry place z Clean and inspect connections and mounting hardware for next winching operation MAINTENANCE 1 Periodically check the tightness of mounting bolts and electrical connections Remove all dirt or corrosion and always keep clean 2 Do not attempt to disassemble the gear box Repairs should be done by the manufacturer or an authorized repair center 3 The gear box has been lubricated using a high temperature lithium grease and is sealed at the factory No internal lubrication is required REPLACING THE WIRE ROPE 1 If the wire rope has become worn or is beginning to show signs of strands breaking it must be replaced before being used again To do this remove the defective rope by free spooling Remove the screw M6x10 Part 950008 on the drum and release the rope 2 Insert the end of the new rope and secure the screw M6 x 10 tightly 3 Engage the clutch and re spool the new rope on the drum keeping tension on the rope as it spools Ensure that the rope is respooling in the under wind position WARNING Only replace the wire rope with the identical replacement part recommended by the manufacturer TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION
12. er switch If the drum is turning and releasing more cable then your connections are accurate If the drum is turning and collecting more cable then reverse the leads on the motor Repeat and check rotation SAFETY PRECAUTIONS A WARNINGAA WARNING DO NOT EXCEED RATED CAPACITY WARNING Intermittent use only WARNING Do not use winch in lifting or moving or persons AXWARNING A minimum of five wraps of cable around the drum barrel is necessary for pulling and holding the rated load The cable clamp is not designed to hold the load without 5 wraps of cable around the barrel WARNING Keep yourself and others a safe distance to the side of the cable when under tension WARNING The wire rope may break before the motor stalls For heavy loads at or near rated capacity use a pulley block snatch block to reduce the load on the wire rope WARNING Never step over a cable or near a cable under load WARNING Don t move the vehicle to pull a load towing on the winch cable This could result in cable breakage WARNING Disconnect the remote control and battery leads when not in use AM WARNING Do not exceed maximum pull rating Avoid shock loads by using the control switch intermittently to take up the slack in the wire rope Shock loads can far exceed the rate capacity for the wire rope and drum XWARNING Do not exceeds maximum line pull ratings shown on the tables WARNING When re spooling the cable ensu
13. nch has been manufactured and tested to the highest standards Please ensure you read and understand the assembly and operating instructions before use Failure to comply with these instructions or any improper use of the equipment will terminate the warranty Please ensure you record the information below Distributor Date of Purchase Invoice No Serial No In the unlikely event you experience problems contact the distributor with this information 16
14. re that the cable spools in the under wind position with the cable entering the drum from the bottom not the top To re spool correctly and while wearing gloves keep a slight load on the cable while pushing the remote button to draw in the cable Walk toward the winch not allowing the cable to slide through your hands Do not let your hands get within 12 of the winch while re spooling Turn off the winch and repeat the procedure until a few feet of cable is left Disconnect the remote control and finish spooling by hand by rotating the drum by hand with the clutch disengaged Keep hands clear of the fairlead and drum while the winch is under power Do not use as a hoist Do not use for overhead lifting Failure to heed these warnings may result in personal injury and or property damage AXWARNING Use gloves to protect hands when handling the cable Never let the cable slide through your hands WARNING Never connect the cable back to itself Apply blocks to the wheels of the vehicle when on an incline No modifications alterations or deviation to the winch are authorized by the manufacturer and SHALL not be made Duration of winching pulls should be kept as short as possible If the motor becomes uncomfortably hot to the touch stop winching immediately and let it cool down for a few minutes Do not pull for more than one minute at or near the rated load AXCAUTION If the motor stalls do not maintain power to the winch
15. ruck beds etc The mounting channel also has holes to accept your roller fairlead 12 Snatch Block If Your winch were supplied with a snatch block that used properly can double the pulling power of winch or change your pulling direction without damaging the wire rope We recommend you to use double line and snatch block for pulling over 85 related line pull WINCH ASSEMBLY AND MOUNTING 9500lbs Red Battery For your choice gt Remote Control Black Battery u Wireless Remote Control NG OPTIONAL a 4 1 Your 9500lb winch is designed with a bolt pattern that is standard in this class of winch Many winch mounting kits are available that utilize this bolt pattern for the most popular vehicle and mounting channels If you cannot find a kit locally contact us and we will provide you with the name of a dealer near you If you will utilize the mounting channel you must ensure that it is mounted on a flat surface so that the three major sections motor drum and gear housing are properly aligned Proper alignment of the winch will allow even distribution of the full rated load 2 Start by connecting the Roller Fairlead Parti 950900 to the Mounting Channel Part 951000 using 2 each of the Cap Screw M10 X 35 Part 950002 Flat Washer Part 950004 Lock Washer Part 950003 and securing with Nut M10 Part 950005 Make sure the screw is placed through the mounting channel and roller fairlea
16. your choice 9 1 R1 Remote control 9 2 R2 Remote control 9 3 R3 Remote control 9 4 Wireless Remote Control THE FOLLOWING DESCRIPTIONS ARE OPTIONAL 001 Snatch Block Pulley 002 Roller Fairlead and Screws 003 Mounting Channel 004 SWR Tensioner INCH ACCESSORIES YOU WILL NEED NOT INCLUDED WITH YOUR WINCH Gloves For handling the wire rope and hook strap Anchor Strap Chain Tree saver anchor straps are made of high quality nylon with high tensile strengths up to 15000lbs QUANTITY 1 4 4 4 4 1 1 1 Heavy Blanket place on the cable to absorb energy should the wire rope break 2 GETTING TO KNOW YOUR WINCH Your 9500Ib winch is a powerful piece of machinery It is important that you understand the basics of its operation and specifications so that when you need to use it you can use it with confidence and safety Below is a list of the components of your winch and their use Practices using your winch before you are in a situation to need to use it 1 Motor Your 5 5 8 3hp motor is powered by a 12 24 volt battery and provides power to the gear mechanism which turns the drum and winds the wire rope Winch Drum The winch drum is the cylinder on which the wire rope is stored It can feed or wind the rope depending on the remote winch switch Wire Rope Your winch has a 3 8 X85 galvanized aircraft cable designed specifically for load capacity of 9500lbs The wire rope
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