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Note: 

This guide is recommended for average vehicle rolling loads. Some applications may require a larger winch 

          than indicated.

5454Kgs/12000LBS Line Pull and Cable Capacity Table

Layer of cable

1

2

3

4

5

Rated line pull  

per layer

Lbs
Kgs

Cable capacity

Ft.
M

12000
5454
16
4.9

9550
4332
36
11

8000
3629
61
18.6

6800
3084
90
27.4

6000
2722
100
30.5

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 cable is winding onto the drum evenly.

 

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.

Winch Operation 

12

OPERATING

:

1

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

 

2. 

P

protector wrapped around a suitably sized tree which will not be damaged by the winching operation.

ull out the winch cable to the desired length and connect to an anchor point. A suggestion would be a tree trunk

 

    

The winch clutch allows rapid uncoiling of the cable 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. Cable 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 cable 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)

• 

• 

• 

• 

• 

• 

• 

Never winch

Check the winch carefully and thoroughly before operating.

 

with your

 

vehicle in gear or in park. This would damage your vehicle's transmission

.

 

 

Never wrap the cable around the object and hook onto the cable itself. This can cause damage to the object being

pulled, and kink or fray

 

the

 

cable

.

Keep hands, clothing, hair

 

and jewellery

 

clear of the drum area and cable when winching

.

Never use the winch if the cable is frayed, kinked or damaged

.

Never allow anyone to stand near the cable, or in line

 

with the cable while it is under load. If the cable 

 

should

 

slip or brake

,

it can suddenly whip back along the line of pull, causing a hazzard for anyone in the area.

Always stand well to the side

 

while

 

winding

.

•  ALWAYS disengage the winch when not in use.

CAUTION:

OFF

ON

OFF

ON

Summary of Contents for 15-6068

Page 1: ...UCT CODE 6068 08 2015 1 CONTENTS 5454kg 12000LB Winch 1 Pair Gloves Control Box C W Attached Cables Fairlead Roller Attachment Kit for Fairlead Roller Clevis Hook Hand Control Battery Included 1SpareAlkaline23A12VBatteryforHandControl Cable to Connect Hand Control to Winch Safety Dampener Blanket Warranty Certificate User Guide Version 2 June 2015 ...

Page 2: ... 7 8 12V DC 4WD WINCH KIT 9 INSTALLATION 10 12 OPERATION 11 5454KGS 12000LBS LINE PULL AND CABLE CAPACITY TABLE 12 13 13 BATTERY REPLACEMENT 14 RECEIVER COMPONENT REPLACEMENT 14 MAINTENANCE 15 DISPOSAL 15 FAQ 15 12V DC 4WD WINCH PARTS LIST DIAGRAM WINCHING PRINCIPLES REMOTE HAND CONTROL OPERATIONS 2 13 Contents SPECIFICATIONS ELECTRICAL CONNECTION ...

Page 3: ...write to us at Natural Product Solutions Pty Ltd Unit 3 60 Box Road TAREN POINT 2229 Telephone 1300 883 104 Email sales 4x4tough com au Website www 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 up...

Page 4: ... hot to touch stop and let it cool for a few 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 Shock 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 ...

Page 5: ...ould be attached to the chassis of the vehicle 9 Ensure rated D or bow shackles are used in conjunction with an approved tree trunk protector to provide a safe anchor point Always use shackles that comply with AS 2741 2002 A 4 7 Tonne shackle is recommended 10 When extending winch cable ensure that at least five wraps of cable remain on drum at all times Failure to do this could result in the cabl...

Page 6: ...t to exceed the Pulling limits of this winch 19 Do NOT drive your vehicle to assist the winch in any way Vehicle movement in combination with winch operation may overload the cable the winch itself or cause damaging shock loads 20 Shock loads when winching are dangerous A shock load occurs when an increased force is suddenly applied to the cable A vehicle rolling back on a slack cable may induce a...

Page 7: ...UM BUSHING 18 2 TIE ROD 19 1 DRIVE SPLINED W RETAINING RING 20 1 DRUM ASSEMBLY 21 1 BUTTON HEAD CAPSCREW 22 1 BRAKE ASSEMBLY 23 1 WIRE ROPE TERMINAL KIT 24 1 WIRE ROPE ASSEMBLY 25 1 CLEVIS HOOK 26 1 MOTOR 27 3 BOOT ELECTRIC TERMINAL 28 1 CABLE ASSEMBLY ELECTRIC 29 1 HEX HEAD CAPSCREW 30 1 WINCH CONTROL 31 1 TO MOTOR FIELD BLUE 32 1 TO MOTOR FIELD RED 33 1 TO MOTOR FIELD YELLOW 34 1 TO POSITIVE TER...

Page 8: ...4X4 Tough 12V DC 4WD Winch Parts List 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 A 18 17 27 26 28 29 22 23 24 25 20 19 17 7 16 38 30 36 37 39 34 33 32 31 35 21 8 ...

Page 9: ...C 4WD Winch Control cable Clevis hook Control box Clutch lever Gear box Motor Battery isolation switch Fairlead roller Remote hand control 9 Wiring connection point for wired hand control lead Dampener Pair of gloves ...

Page 10: ...e 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 mounti...

Page 11: ...g red cable positive 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 connecting to positive terminal of the battery CAUTION 1 Your battery must be kept in good condition 2 Be sure batter...

Page 12: ...d uncoiling of the cable 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 Cable 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 ...

Page 13: ...lutch Sliding ring gear Dimensions 548mmx160mmx218mm Braking Action Automatic in the drum NW 38kg 84Lbs Battery Recommended 650 CCA minimum for winching Mounting Bolt Pattern 254mmx114 3mm Line pull Lbs 0 2000 4000 6000 8000 9500 Kgs 0 907 1814 2722 3629 4310 Line speed FPM 25 6 16 11 9 9 79 8 01 5 9 MPM 7 8 4 88 3 63 2 98 2 44 1 8 Motor current Amps 80 130 180 230 290 350 Remote Hand Control Oper...

Page 14: ...t To open remote hand control unscrew 4 screws and carefully pull apart the two halves Battery Figure 1 Figure 2 Figure 3 Remote hand control To access the battery pull off the IN OUT toggle switch assembly which is inserted into the 6 recesses on the circuit board Bend the front of the printed panel forward Once the battery is replaced ensuring the polarity orientation is correct ie Match to put ...

Page 15: ...y operate if the vehicle is running 15 It is highly recommended that the winch be used regularly once a month Simply power the cable out 15m free spool 5m 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...

Page 16: ...16 4x4 TOUGH GO OFF ROAD is a trademark of Natural Product Solutions Pty Ltd Unit 3 60 Box Road Taren Point NSW 2229 Phone 1300 883104 www 4x4tough com au sales 4x4tough com au ...

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