Ironman4x4 Monster Winch, User Manual

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USER GUIDE
Spooling Out
The quickest and easiest way spool the cable out from the drum is to free spool it with the
clutch handle in the disengaged position. To do this power the winch out slightly to take the
tension฀off฀the฀cable฀and฀rotate฀the฀clutch฀handle฀to฀the฀disengage฀position,฀and฀pull฀the฀cable฀
out to the chosen anchor point. The other option is to power the cable out which is a much
slower฀process฀and฀will฀heat฀up฀the฀brake฀in฀the฀cable฀drum,฀this฀is฀not฀recommended.฀
฀ ฀ ฀Note:฀Always฀leave฀at฀least฀5฀wraps฀of฀cable฀on฀the฀drum.฀Although฀the฀end฀of฀the฀
cable฀is฀attached฀to฀the฀drum฀with฀a฀lug,฀it฀is฀not฀designed฀to฀hold฀any฀load฀and฀will฀
tear off the end of the cable or may damage the cable lug if less than 5 wraps remain
on the drum. If this happens it will not be covered by warranty.
Spooling in with no load
Before spooling cable please refer to the safety section of this manual.
Clutch฀handle฀will฀need฀to฀be฀in฀the฀engaged฀position฀for฀this฀process.฀
When spooling the cable onto the winch for storage it is important that it is wound tightly and
evenly฀onto฀the฀drum.฀To฀do฀this฀refer฀to฀the฀cable฀pre-tensioning฀section฀on฀Page฀6,฀or฀have฀
an฀assistant฀hold฀as฀much฀tension฀as฀possible฀onto฀the฀hook,฀using฀the฀hook฀strap,฀and฀walk฀
towards the winch while you operate the hand control and guide the cable evenly onto the
drum.฀The฀hook฀can฀be฀pulled฀firmly฀against฀the฀fairlead฀or฀anchored฀to฀a฀recovery฀hook฀on฀the฀
vehicle.
฀ ฀ ฀Note:฀Do฀not฀over฀tension฀cable฀or฀damage฀may฀occur฀to฀fairlead,฀winch฀bar฀or฀
recovery฀hook฀on฀vehicle.฀Care฀must฀be฀taken฀not฀to฀get฀hands฀caught฀in฀cable,฀
fairlead฀or฀any฀other฀moving฀parts฀of฀winch.฀Always฀use฀the฀hook฀strap฀and฀gloves฀
when฀re-spooling฀the฀cable฀never฀use฀bare฀hands.฀Always฀make฀sure฀that฀cable฀for฀
hand controller is kept well away from cable or any other moving parts to prevent it
from becoming tangled.
Pre-Tensioning
It฀is฀very฀important฀to฀pre฀tension฀the฀cable฀before฀the฀first฀time฀the฀winch฀is฀used.฀Failure฀to฀do฀
this will dramatically shorten the life of the cable and will not be covered by warranty.
To฀do฀this฀the฀following฀procedure฀must฀be฀followed:฀
1. Find a fairly level or slightly inclined surface that has enough room to spool the cable off the
drum down to the last 5 wraps of the drum.
2. Turn the clutch handle on the winch gearbox to the disengage position and pull the cable out
to฀the฀last฀5฀wraps฀on฀the฀drum.฀Never฀unwind฀the฀cable฀to฀less฀than฀5฀wraps฀on฀the฀drum.฀
Although฀the฀end฀of฀the฀cable฀is฀attached฀to฀the฀drum฀with฀a฀lug,฀it฀is฀not฀designed฀to฀hold฀
any load and will tear off the end of the cable or may damage the cable lug if less than 5
wraps remain on the drum. If this happens it will not be covered by warranty.
3. Turn the clutch handle on the winch gearbox to the engaged position.
4. Securely attach the hook end of the cable to a suitable anchor point and slowly back the
vehicle away until the slack is taken out of the cable.
To pretension the cable properly it will need to be spooled back onto the drum evenly with a
load฀of฀at฀least฀450฀kg฀(1000฀lbs).฀This฀load฀can฀be฀applied฀by฀lightly฀engaging฀the฀hand฀brake฀
or฀having฀a฀second฀person฀lightly฀applying฀the฀foot฀brake฀while฀re-spooling฀the฀cable.
5.฀ ฀Start฀the฀engine฀of฀the฀vehicle.฀Using฀your฀hand฀controller,฀start฀to฀re-spool฀the฀cable฀back฀
onto the drum so that it spools evenly with no gaps between each wind. If gaps occur
unwind฀the฀cable฀slightly฀and฀then฀re-spool฀it.฀Note:฀Extreme฀care฀must฀be฀taken฀not฀to฀get฀
your hand caught in the fairlead or any moving parts of the winch.
6.฀ ฀Once฀the฀cable฀has฀spooled฀to฀within฀2฀metres฀of฀the฀hook,฀stop฀winching฀and฀apply฀the฀
hand฀brake฀of฀the฀vehicle฀firmly.฀Reverse฀the฀winch฀slightly฀to฀release฀the฀load฀from฀the฀
cable.
7. Unhook the cable from its anchor. While holding onto the hook with the supplied hook strap
spool the remainder of the cable in. The hook can attached to a recovery point on the vehicle
or carefully winched in against the fairlead taking care not to over tension it or this could
cause damage to the vehicle or bull bar.
Always฀use฀supplied฀hook฀strap฀when฀spooling฀cable฀to฀prevent฀hands฀from฀getting฀caught฀in฀
fairlead or other moving parts.
During฀heavy฀winching฀heat฀will฀build฀up฀in฀the฀electric฀motor.฀Periodically฀stop฀winching฀and฀
touch฀the฀motor฀with฀your฀bare฀hand,฀if฀it฀is฀uncomfortably฀hot฀to฀touch฀stop฀winching฀for฀long฀
enough฀for฀it฀to฀cool฀down.฀Failure฀to฀do฀this฀could฀cause฀damage฀the฀motor,฀Which฀will฀not฀be฀
covered by warranty.
WARNING:
฀Never฀operate฀winch฀with฀less฀than฀5฀wraps฀on฀the฀drum.฀
Cable฀could฀come฀adrift฀from฀the฀drum฀as฀the฀attaching฀lug฀is฀not฀
designed to hold any load
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