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Smittybilt XRC10, Installation Manual

The Smittybilt XRC10 is a high-performance winch designed to tackle the toughest off-road challenges. Ensure a hassle-free installation with the comprehensive Installation Instructions Manual. Download this manual for free at manualshive.com, and embark on your next adventure equipped with the knowledge you need to maximize the potential of your XRC10.

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Installation Manual 

XRC 8 WINCH PARTS LIST 

No.

 

Parts No.

 

Description 

Qty

 

No.

 

Part No.  Description 

Qty

 

01 

97281-01  Sun Gear-Input 

1 

27 

97281-27

 

Inner Gear 

1 

02 

97281-02  Gear Carrier-Input 

1 

28 

97281-28

 

Clutch Gear 

1 

03 

97281-03  Gear Carrier-Intermediate 

1 

29 

97281-29

 

Gear Box Tube 

1 

04 

97281-04  Washer-1.2mm thickness 

2 

30 

97281-30

 

Gasket 

1 

05 

97281-05  Gear Carrier-Output 

1 

32 

97281-32

 

Gear Box End Cover 

1 

06 

97281-06  Outer Spline 

1 

33 

97281-33

 

Bolt + Spring Washer 

10 

07 

97281-07  Spline Positioning Bolt 

1 

34 

97281-34

 

Shaft Sleeve 

1 

08 

97281-08  Drum 

1 

35 

97281-35

 

Washer 

1 

09 

97281-09  Brake Positioning Bolt 

1 

36 

97281-36

 

Bearing 

1 

10 

97281-10  Brake System 

1 

37 

97281-37

 

Clutch Spring 

1 

11 

97281-11  Coupling Joint 

1 

38 

97281-38

 

Locking Pin 

1 

12 

97281-12  Rotor

 

1 

39 

97281-39

 

Clutch Lever 

1 

15 

97281-15  Motor Long Bolts 

2 

40 

97281-40

 

Clutch Steel Ball 

1 

16 

97281-16  Motor End Cover 

1 

41 

97281-41

 

Wire Rope 

1 

17 

97281-17  Carbon Frame & Brush Assy

 

1 

42 

97281-42

 

Wire Rope Fix Bolt 

1 

18 

97281-18  Stator 

1 

43 

97281-43

 

Screw 

4 

19 

97281-19  Tie Rod Bolt 

4 

44 

97281-44

 

Spring Washer 

4 

20 

97281-20  Motor Base 

1 

45 

97281-45

 

Winch Mount Bolt 

4 

21 

97281-21  Nylon Bearing 

2 

46 

97281-46

 

Clevis Hook 

1 

22 

97281-22  Tie Rod 

2 

47 

97281-47

 

Roller Fairlead 

1 

23 

97281-23  Bolt 

10 

48 

97281-48

 

Fairlead Mount Bolt/Nut

 

2 

24 

97281-24  Spring Washer 

10 

49 

97281-49

 

Control Box 

1 

25 

97281-25  Gear Box Base 

1 

50 

97281-50

 

Remote Control 

1 

26 

97281-26  Gasket 

1 

Summary of Contents for XRC10

Page 1: ...o 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 tables Shock loads must not exceed these ratings 5 Avoid Unintentional Starting Winch clutch should be disengaged when not in use and fully engaged when in use 6 Check Damaged Parts Before using you should check your winch carefully Any part that is d...

Page 2: ...ing the winch hook should be attached to the chassis of the vehicle 8 Ensure rated D or bow shackles are used in conjunction with an approved tree trunk protector to provide a safe anchor point 9 When extending winch cable ensure that at least FIVE 5 wraps of cable remain on drum at all times Failure to do this could result in the cable parting from the drum under load Serious personal injury or p...

Page 3: ... locktite or the cable clamp thread Tighten the clamp screw properly but do not over tighten The lockkite will prevent loosening of the screw in arduous conditions Locktite 7471 primer and 222 Thread Locker are recommended 17 Do not attempt to exceed the pulling limits of this winch 18 Do not drive your vehicle to assist the winch in any way Vehicle movement in combination with winch operation may...

Page 4: ...nd or Frontal Protection Systems to suit most popular vehicles Winch frames are packaged with detailed instructions 3 Should you wish to manufacture your own mounting plate the dimensions below will assist A steel mount plate of 6mm thickness is recommended Fasteners should be steel high tensile grade 5 or better A poorly designed mount may void warranty 4 The winch should be secured to the mounti...

Page 5: ...Installation Manual ...

Page 6: ...s adequate A fully changed battery and proper connections are essential Run the vehicle engine during winching operations to keep charged Pay close attention to proper electrical cable connection as follows refer to Diagram 1 Be sure to observe the following steps for a correct and safe electrical connection 1 Short Red cable B connecting to the red terminal B of winch motor 2 Short black cable wi...

Page 7: ...duce performance or may cause a short 4 Clean all connections especially in remote control switch and receptacle 5 In salty environments use a silicone sealer to protect from corrosion 6 Index the heads of the plate studs into the keyhole slots on the back of the winch 7 Attached the winch Adaptor plate assembly to your trailer hitch by inserting the trailer hitch ball through the shaped hole in t...

Page 8: ...before proceeding 4 Plug in the winch hand control It is recommended that the winching operation takes place from the driver s position to ensure safe operation Turn control base clockwise until it locks into place 5 To commence winching operation start vehicle engine select in transmission maintain engine speed at idle 6 Operate the remote control switch to IN or OUT until the vehicle has been re...

Page 9: ...your authorized outlet for technical assistance and repairs SPARE PARTS A comprehensive range of spare parts is available For further information please contact Smittybilt Automotive Products NOTE The safety precautions and instructions discussed in this manual can t cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are ...

Page 10: ... Way Roller Remote Control Included Recommended Battery 650CCA Minimum for Winching Battery Leads 25mm2 72 1 8m Finish Black Gross Weight 94 0lbs 42 5Kgs Mounting Bolt Pattern 10 0 x 4 50 Line speed and amp draw first layer Line Pull Lbs NO LOAD 2000 4000 6000 8000 Kgs 910 1814 2720 3630 Line Speed Fpm 37 2 18 13 1 10 2 8 2 Mpm 11 4 5 5 4 1 3 2 2 6 Motor Current Amps 75 195 260 335 410 Line pull a...

Page 11: ...97281 36 Bearing 1 10 97281 10 Brake System 1 37 97281 37 Clutch Spring 1 11 97281 11 Coupling Joint 1 38 97281 38 Locking Pin 1 12 97281 12 Rotor 1 39 97281 39 Clutch Lever 1 15 97281 15 Motor Long Bolts 2 40 97281 40 Clutch Steel Ball 1 16 97281 16 Motor End Cover 1 41 97281 41 Wire Rope 1 17 97281 17 Carbon Frame Brush Assy 1 42 97281 42 Wire Rope Fix Bolt 1 18 97281 18 Stator 1 43 97281 43 Scr...

Page 12: ...Installation Manual XRC 8 DRAWING ...

Page 13: ...e Control Included Recommended Battery 650CCA Minimum for Winching Battery Leads 25mm2 72 1 8m Finish Black Weight 99 0lbs 42 5Kgs Mounting Bolt Pattern 10 0 x 4 50 Line speed and amp draw first layer Line Pull Lbs NO LOAD 2000 4000 6000 8000 10000 Kgs 910 1814 2720 3630 4535 Line Speed Fpm 29 53 14 44 12 14 10 17 8 86 7 38 Mpm 9 4 4 3 7 3 1 2 7 2 25 Motor Current Amps 70 170 240 310 380 425 Line ...

Page 14: ...e System 1 07 97210 07 Gear Carrier Input 1 23 97210 23 Coupling Joint 1 08 97210 08 Gear Carrier Intermediate 1 24 97210 24 Winch Mount Bolt 4 09 97210 09 Washer 1 2mm thickness 2 25 97210 25 Motor Base 1 10 97210 10 Clutch Gear 1 26 97210 26 Rotor 1 11 97210 11 Gear Carrier Output 1 27 97210 27 Stator 1 12 97210 12 Gear Box Tube 1 28 97210 28 Carbon Frame Brush Assy 1 13 97210 13 Clutch Handle A...

Page 15: ...Installation Manual XRC 10 DRAWING ...

Page 16: ...ontrol Included Recommended Battery 650CCA Minimum for Winching Battery Leads 25mm2 72 1 8m Finish Black Weight 99 0lbs 45 0Kgs Mounting Bolt Pattern 10 0 x 4 50 Line speed and amp draw first layer Line Pull Lbs NO LOAD 2000 4000 6000 8000 10000 12000 Kgs 907 1814 2722 3630 4532 5440 Line Speed Fpm 23 5 12 8 10 5 9 4 7 4 6 3 5 Mpm 7 2 3 9 3 2 2 9 2 3 1 9 1 5 Motor Current Amps 65 120 165 215 270 3...

Page 17: ...212 10 Bolt 1 35 97212 35 Washer 1 11 97212 11 Brake Assy 1 36 97212 36 Washer 1 12 97212 12 Coupling Joint 1 37 97212 37 Clutch Steel Ball 1 13 97212 13 Rotor 1 38 97212 38 Connection of Clutch Handle 1 15 97212 15 Motor Long Bolt 2 40 97212 40 Wire Rope 1 16 97212 16 Motor End Cover 1 41 97212 41 Screw 4 17 97212 17 Carbon Assy 1 42 97212 42 Lock Washer 4 18 97212 18 Stator 1 43 97212 43 Mountin...

Page 18: ...Installation Manual XRC 12 DRAWING ...

Page 19: ...ntrol Included Recommended Battery 650CCA Minimum for Winching Battery Leads 25mm2 72 1 8m Finish Black Weight 143 0lbs 65 0Kgs Mounting Bolt Pattern 10 0 x 4 50 10 0 x 6 50 Line speed and amp draw first layer Line Pull Lbs NO LOAD 3000 6000 9000 12000 15000 Kgs 1360 2720 4080 5440 6800 Line Speed Fpm 21 3 11 5 7 2 5 6 4 9 3 6 Mpm 6 5 3 5 2 2 1 7 1 5 1 1 Motor Current Amps 65 140 270 295 360 420 L...

Page 20: ...ng 1 11 97215 11 fixing sleeve 1 37a 97215 37a Shaft Sleeve 1 12 97215 12 Rotor 12V 1 37b 97215 37b Washer 1 13 97215 13 Bolt M5 20 4 37c 97215 37c Clutch 1 14 97212 14 Washer 18 2 37d 97215 37d Clutch Bolt 1 15 97215 15 Tie Rod Bolt 6 37e 97215 37e Clutch Spring 1 16 97215 16 Motor End Cover 1 39 97215 39 Bolt 8 17 97215 17 4 5 Carbon Assy 1 41 97215 41 Wire Rope 1 18 97215 18 Stator 12V 1 42 972...

Page 21: ...Installation Manual XRC 15 DRAWING ...

Page 22: ...h pressed If voltage is present replace motor Drain and dry Run in short bursts without load until completely dry Motor runs too hot Long period of operation Let winch cool down periodically Motor runs slowly or without normal power Battery runs down Insufficient current or voltage Recharge battery by running vehicle s engine Clean tighten or replace the connector Motor runs but cable drum does no...

Page 23: ...ion or improper service or iii any normally wearable part such as the break mechanism This Warranty is void if any SAP serial number has been removed or defaced Commercial or industrial use or application or any hoisting application also voids warranty of the winch voids the Warranty This Warranty is good only for winches bought sold and used in the United States unless otherwise specifically agre...

Page 24: ... state to state Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply as to you Also some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you Smittybilt reserves the right to discontinue product lines and substitute products or provide other rem...

Page 25: ... installing any accessory check state laws and assure that the accessory will not obscure any lights or interfere with proper operation on your vehicle s safety equipment Consult your owner s manual and the Smittybilt instructions or additional safety information Smittybilt products nor the warnings contained herein are not a substitute for your safe driving Don t drink and drive always use seat b...

Page 26: ...brackets on top hook facing forward and secure with included bolts Fig B C STEP 3 Place solenoid on top of tie rods with hooks facing forward in desired location Secure by tightening the screws in the rear Fig D E Installation is now complete Use the wiring diagram in instruction manual for further assembly Fig A Fig B Fig C Fig D Fig E Tie Rod over cable Mounting Instructions ...

Page 27: ...ver the hole and re install tie rod bolt Do not tighten completely Fig B STEP 3 Loosen Back Out the two screws on the side of the solenoid box and place bracket over the two bolts and slide the solenoid box back and tighten the bolts securely Fig C D Fig A Fig B Fig C Fig D STEP 4 Lower down the solenoid box and attach the front of the bracket securely to the mounting location on the front of the ...

Page 28: ...Installation Manual STEP 5 Tighten the rear tie rod bolt completely now Fig F G Installation is now complete Use the wiring diagram in instruction manual for further assembly Fig E Fig F Fig G ...

Page 29: ...cap using a 3mm allen tool Fig A Carefully remove end cap from housing Use care in order not to damage the gasket Step2 Using a scribe or some other type of slim pointed tool push up and out the small holding rod pin Fig B Step3 Slowly pull out the clutch lever from the end cap Do this slowly and on a flat clean surface Use caution when doing so there is a spring and ball bearing that will be reve...

Page 30: ... D Step 5 Push the lever all the way in so it s flush with the end cover you will hear the bearing click into its place in the cavity hole on the clutch lever Then turn lever clockwise until it is sticking straight up Fig E F Step 6 Now insert new holding pin rod through hole in clutch lever on the inside of the cap Push it down all the way until it is flush with the top of the lever Fig G H ...

Page 31: ...Re install gear cover back onto winch using the previously removed bolts Fig J Step 9 Once all bolts are tighten check operation of new clutch lever by turning between engaged mode and free spool mode You should feel the click and feel it lock into position Installation is now complete ...

Page 32: ...Installation Manual Winch Motor Clocking 97281 97210 Step 1 To clock the winch motor which can be achieved without taking the Step 3 Reinstall Long Bolts to complete ...

Page 33: ...Installation Manual Step3 get gear box rotated then connect the gear box with the gear box base again After that connect the gear box with the tie rod ...

Page 34: ...er ________________________________________________________________________ Date of Purchase _______________________________________________________________________ Where did you purchase this product _______________________________________________________ Store or catalog name ____________________________________________________________________ Store Location _____________________________________...

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