Installation of the Winch
ATTACHING THE HANDLE
1. Turn handle adaptor clockwise until ratchet
has engaged.
2. Attach the handle once the ratchet has
engaged.
INSTALLING THE WINCH
1. Locate the winch in an area clear of traffic
and obstacles that could interfere with
its operation. Make sure the winch is
accessible for maintenance and operation.
2. The winch should be positioned onto a
solid / flat foundation base able to support
the winch and the load / unload operations
under all conditions.
3. Fasten the winch securely to the mounting
(base), utilising all four mounting holes
to ensure maximum capacity. 4ea. M10
galvanised or G316 stainless steel bolts,
flat and spring washers and nuts should be
used to secure the winch to its mounting.
INSTALLING WIRE CABLE / ROPE
Keep the following in mind when selecting.
Contact a reputable supplier for assistance.
1. Breaking strength of new wire cable / fibre
rope should be at least 2 times greater than
the rating of the winch.
2. Wire cable/fibre rope lay must agree with
the winding direction of the drum to insure
proper winding.
3. Secure the wire cable / fibre rope to the
winch drum as per the securing instructions
below.
4. Test the wire cable / fibre rope installation
by operating the winch.
5. Wind three full turns of wire cable onto the
drum by operating the winch whilst holding
the wire cable taut. These turns serve as
an anchor wraps and must remain on the
drum at all times.
Dependant on Winch model, two securing
methods for cable are applicable:
Instruction for securing a cable to a winch
using a plate clamp fitting:
1. Tape the cable end using 50mm – 70mm
of plastic tape. This is to stop the cable end
from fraying and causing injury in use.
2. Fold the end of the cable (approximately
30mm) back on itself and permanently kink
the end.
3. Feed the taped end of the cable through
the round hole of the drum flange (disc)
from inside the drum.
4. Place one of the cup head bolts into Hole 1
of the clamp fitting, with the head on the
inside of the drum assembly, and pull the
cable tight against the bolt. Attach the nut
and tighten.
5. Align the second hole in the plate with Hole
2, and secure with the second bolt and nut.
Instruction for securing a cable to a winch
using a single bolt fitting
1. Place the cup headed bolt into the square
hole with the head on the inside of the
drum assembly.
2. Screw on the combination nut and washer
only 2-3 threads.
3. Tape the cable end using 50mm – 70mm
of plastic tape. This is to stop the cable end
from fraying and causing injury in use.
4. Feed the taped end of the cable through
the round hole of the drum flange (disc)
from inside the drum and double back to
loop the cable under the bolt, behind the
washer and back towards the round hole.
5. While holding the cable in place under the
nut with the left hand, pull the cable tight
with the right hand.
6. Using the thumb of the left hand hold the
cable in place inside the drum and tighten
the nut to secure the cable in place.
Turn the handle to wind the wire cable
onto the winch drum. Uniformly wind the
wire cable onto the winch drum by holding
the wire cable taut.
Instruction for securing fibre rope to winch
– Note: Fibre rope to be ≤ Ø7mm
1. Take the winch drum with the gear facing
the assembler and the free end of the rope
and wrap three turns around the hub of the
drum in an anticlockwise direction.
2. Take the free end and pass it between the
three turns and the drum hub and then
pass the free end over the three turns on
the drum and under the last turn.
3. Pass free end of the rope under the last bite
and through the ‘cable’ hole in the flange.
Pull firmly so that the turns on the drum
lie reasonably flat. The length protruding
needs to be about 150mm.
4. Insert from inside the drum flange (centre
hole) the M6 square neck cup head bolt
and screw the M6 flanged serrated hexagon
nut onto the bolt.
5. Wrap the rope around the M6 bolt inside
the flanged serrated hexagon nut. Secure
the fibre rope by tightening the nut using
an M6 spanner. When securing, ensure that
the rope fibres do not catch on the bolt
threads and that the rope stays inside the
flanged section. Trim any excess rope.
6. The turns around the drum will have
become loose. Work the turns so that the
rope lays flat against the hub and there is
no slack.
IMPORTANT:
Inspect the winch immediately
following installation. This will give
provide a record of the condition of
the winch from which to compare
future inspections.
IMPORTANT:
Use wire cable/fibre rope and other
rigging equipment rated for the capacity
of the winch.
Do not drag the wire cable/fibre rope
through dirt or debris that could cause
damage, or poor operation.
Always wear protective clothing when
handling wire cable.
Install the wire cable/fibre rope securely
to the winch drum. A poorly secured wire
cable/fibre rope could come loose from
its anchor and could release the load.
Ensure the wire cable/fibre rope is
wound correctly or the winch may not
work properly and could release the
load.
Always ensure that a minimum of three
full turns remain on the winch drum at
all times.
WARNING:
Do not install the winch near corrosive
chemicals, flammable materials or
other elements that may damage
the winch or injure the operator.
Adequately protect the winch and
operator from such elements.
Position the winch so the operator
can stand clear of the load, and out of
the path of possible broken wire cable
that could snap back and cause injury.
Attach the winch to a rigid and level
foundation that will support the winch
and its load under all load conditions,
including shock loading.
DO THE FOLLOWING:
• Read carefully and comply with the
guidelines set forth in this Operating
Manual.
• Keep hands away from the drum, gears,
wire cable and other moving parts of the
equipment. Install the wire cable/fibre
rope securely to the winch drum.
• Keep your clothing clear of the cable,
rope and hook and its opening during
operation and/or when spooling.
• Tighten the brake winch handle adapter
before use to ensure optimal braking
ability.
• Ensure cable/rope is secured correctly
before use of the brake winch.
• Cable/rope is required to be wrapped
around drum a minimum 3 times, at all
times.
• Regularly examine all parts of the brake
winch and do not use if damaged. Repair
or replace any defective parts of the
brake winch.
• Keep out of the path of the load should
the wire cable/fibre rope break and snap
back and cause injury.
TEMPERATURE
• Winches may be operated in
temperatures from -25°C to +49°C
• Winches may be stored in temperatures
from -25°C to +63°C
• Winches shall not be forcefully or
rapidly cooled or heated. For example,
winches shall not be placed into sub-zero
refrigerated transport modules, nor
subjected to heat guns or gas torches.
DO NOT DO THE FOLLOWING:
• Do not lift people or lift a load over
people. Alert all people in close
proximity and keep non-operating users
away from the working area before use
of the brake winch.
• Never lift more than the capacity stated
on the brake winch.
• Never apply a load on the brake winch
with the cable in full extension.
• Do not walk or work under a load or in
the line of force of any load.
• Do not exceed the load rating of the
winch or any other component in the
system. To do so could result in failure of
the equipment.
• Do not use more than one winch to move
a load that exceeds the load rating of a
single winch. A shift in load weight could
overload the equipment.
• Do not use damaged or malfunctioning
equipment. To do so could result in
failure of the equipment.
• Do not modify the equipment in any way.
To do so could cause equipment failure.
• Never lubricate (grease) the braking
mechanism of the brake winch.
• Do not apply a load on the winch with
the wire cable/fibre rope fully extended.
• Never disengage the clutch while the
cable/rope is under tension.
• Never engage the clutch while the drum
is rotating.
• Never winch when there are less than
3 wraps of cable/rope on the drum.
• Never wrap the cable/rope around a load
as this will damage the cable/rope.
• Do not swing the load as this may cause
damage.
• Never leave a suspended load
unattended.
• Do not wrap the wire cable/fibre rope
around the load. This may damage the
wire cable/fibre rope and could cause the
load to fall. Use a sling or other approved
lifting device.
• Do not divert your attention from the
operation. Stay alert to the possibility of
accidents, and try to prevent them from
happening.
• Do not jerk or swing the load. Avoid
shock loads by starting and stopping the
load smoothly. Shock loads overload the
equipment and may cause damage.
• Do not leave a suspended load
unattended unless specific precautions
have been undertaken and keep people
away from the winch and out from under
the load.
GENERAL THEORY OF OPERATION
IMPORTANT: Limit non-uniform winding
by keeping tension on the wire cable. It
is the operators responsibility to detect
and account for different factors affecting
the condition and performance of the
equipment.
The pull required
to move the load must not
exceed the load rating of the winch. Consider
the total force required to move the load, not
the weight of the load.
The winch can
develop forces that will
exceed the load rating. It is the responsibility
of the winch operator to limit the size of the
load. Inspect the winch regularly for damage
according to the instructions contained in the
Owner’s Manual.
Performance ratings
of the winch are
affected by the amount of wire cable wound
onto the drum, the way in which it is wound,
and the way the winch is used.
Drum capacity
depends on how tightly and
evenly the wire cable is wound onto the
drum. Actual drum capacities are usually
25-30% less than the values shown in
performance tables, due to loose winding and
overlapping.
Load rating
represents the maximum pull
that can be placed on a new winch. Load
ratings are assigned values for specific
amounts of load travel or wire cable
accumulation. The load rating decreases as
layers of wire cable accumulate on the drum.
Duty ratings
refer to the type of use the winch
is subject to. Consider the following when
determining duty rating:
Environment:
harsh environments include
hot, cold, dirty, wet or corrosive surroundings.
Protect the winch against harsh environments
when possible.
Maintenance:
poor maintenance, meaning
poor cleaning, lubrication or inspection, leads
to poor operation and possible damage of
the winch. Minimise poor maintenance by
carefully following the instructions contained
in the Owner’s Manual.
Loading:
severe loading includes shock
loading and moving loads that exceed the
load rating of the winch. Avoid shock loads,
and do not exceed the load rating of the
winch.
Frequency of operation:
frequent or lengthy
operations increase wear and shorten the life
span of gears, bushes, and other components.
Increase maintenance of the winch if used in
frequent operations.
Important Safety Information
