Smittybilt 97203 Installation Instructions Manual Download Page 12

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For Technical Support/Warranty Information please call 310-762-9944

Smittybilt, 400 West Artesia Blvd, Compton, CA 90220

Installation Instructions

XRC 3.0 3,000lb Winch

Part # 97203

S.B part#

QTY

Description

97203-01

Motor

97203-02

gasket

97203-03

bearing

97203-04

bearing bushing

97203-05

brake base

97203-06

brake gear

97203-07

drum support motor side

97203-08

drum bushing

97203-09

tie rod

97203-10

bushing for water proof

97203-11

o-ring for water proof

97203-12

drum

97203-13

spring

97203-14

Split snap ring

97203-15

shaft

97203-16

gear box cover

97203-17

Gasket

97203-18

splined gear

97203-19

Gear carrier assembly state 3

97203-20

Gear carrier assembly state 2

97203-21

Gear carrier assembly state 1

97203-22

sun gear

97203-23

gasket

97203-24

Slide block for clutch

97203-25

gear ring

97203-26

gear box body

97203-27

bushing

97203-28

clutch knob

97203-29

wire rope and hook

97203-30

Remote

97203-31

Handle Bar Control

97203-32

Winch Plate

97203-33

Solenoid

Summary of Contents for 97203

Page 1: ...D MOUNTING 1 Your winch is designed with a bolt pattern that is standard in this class of winches Many winch mounting kits are available that utilize this bolt pattern for the most popular ATV s and mounting channels 2 Regardless of the mounting kit you use ensure that your winch is mounted on a flat surface so that the three major sections motor drum and gear housing are properly aligned Proper a...

Page 2: ...ack 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 then turn the clutch knob to the in position to engage the gears Press the cable out button...

Page 3: ...r mounted mini rocker switch and remote socket Mounting locations may vary depending on the make and model of the ATV Read and understand the following instructions to choose the appropriate mounting locations It is recommended that the switch be installed on left handlebar A piece of electrical tape around the handlebar will help prevent rotation of mount on the handle bar Do not tighten over and...

Page 4: ... call 310 762 9944 Smittybilt 400 West Artesia Blvd Compton CA 90220 Installation Instructions XRC 3 0 3 000lb Winch Part 97203 Handlebar mount Exact location may vary depending on ATV make and model Mini rocker switch assembly Use a test light to locate a suitable wire ...

Page 5: ...a safe distance to the side of the cable when under tension The wire rope may break before the motor stalls For heavy loads at our near rated capacity use a pulley snatch block to reduce the load on the wire rope Never step over a cable or near a cable under load Don t move the vehicle to pull a load towing on the winch cable This could result in cable breakage Disconnect the remote control and ba...

Page 6: ...gaged Keep hands clear of the fairlead and drum while the winch is under power Failure to heed these warnings may result in personal injury or property damage CAUTION Use gloves to protect hands when handling the cable Never let the cable slide through your hands Apply blocks to the wheels of the vehicle when on an incline No modifications alterations or deviation to the winch are authorized by th...

Page 7: ...et 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 ect Inspect the wire rope and equipment before each use A frayed or damaged cable should be replaced immediately Use only manufacturer s identical replacement cable ...

Page 8: ...ttach clevis hook back onto cable as this could cause damage to the cable Self Recovery Do not winch from an acute angle as the wire rope will pole up on one side of the drum causing damage to the wire rope and winch Short pulls from an angle can be used to straighten the vehicle When 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...

Page 9: ...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 winding process Avoid shock loads keep the wire rope under tension P The vehicle to be winched should be place 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...

Page 10: ... a high temperature lithium grease and is sealed at the factory No internal lubrication is required REPLACING THE WIRE CABLE 1 If the wire cable 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 cable be free spooling it out Remove the 5 x 5mm bolt on the drum and release the cable 2 Insert the end of the n...

Page 11: ...MITTYBILT COM For Technical Support Warranty Information please call 310 762 9944 Smittybilt 400 West Artesia Blvd Compton CA 90220 Installation Instructions XRC 3 0 3 000lb Winch Part 97203 TROUBLE SHOOTING ...

Page 12: ...shing for water proof 11 97203 11 2 o ring for water proof 12 97203 12 1 drum 13 97203 13 1 spring 14 97203 14 2 Split snap ring 15 97203 15 1 shaft 16 97203 16 1 gear box cover 17 97203 17 1 Gasket 18 97203 18 1 splined gear 19 97203 19 1 Gear carrier assembly state 3 20 97203 20 1 Gear carrier assembly state 2 21 97203 21 1 Gear carrier assembly state 1 22 97203 22 1 sun gear 23 97203 23 1 gaske...

Page 13: ...WWW SMITTYBILT COM For Technical Support Warranty Information please call 310 762 9944 Smittybilt 400 West Artesia Blvd Compton CA 90220 Installation Instructions XRC 3 0 3 000lb Winch Part 97203 ...

Page 14: ...310 762 9944 Smittybilt 400 West Artesia Blvd Compton CA 90220 Installation Instructions XRC 3 0 3 000lb Winch Part 97203 XRC 3 0 3 000lb WINCH Line Pull lbs 0 1000 2000 3000 kg 0 454 907 1361 Line Speed ft min 24 5 14 7 10 5 6 9 m min 7 5 4 5 3 2 2 1 Motor Amps 15 75 120 175 ...

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