2. In order to release a load without power, rotate the
knob or clutch lever slowly and carefully forward
toward “Freewheel.” When the load begins to move, it
can be controlled by the knob or clutch lever. Careful,
slow movement of the knob or lever will provide
smooth control of the load.
WARNING: ALWAYS MAINTAIN CONTROL OF THE
LOAD. ALLOWING EXCESS SPEED COULD
RESULT IN WINCH DAMAGE AND SEVERE PER-
SONAL INJURY.
3. Remember that the gear train and brake mechanism
are completely disengaged in the “Free Wheel” posi-
tion and in order to power the winch or hold a load in
position, the knob or lever must be returned to the
“Engaged” position.
NOTE: On the TW9000 it is not necessary to turn the
clutch lever completely to the “Engaged” position man-
ually. The spring tension built into the winch provides
adequate force on the clutch lever.
CAUTION: Never force knob or clutch lever in
either direction.
An emergency crank handle is provided for the model
TW9000 for use in the event of a power failure. The model
TW4000 requires the use of a ratchet wrench and 5/8"
deep well socket or a standard 5/8" socket with an exten-
sion.
1. Disconnect the electrical power from the winch and
remove the plastic plug from the side of the winch
housing.
WARNING: NEVER OPERATE THE WINCH ELEC-
TRICALLY WITH THE EMERGENCY HANDLE OR
RATCHET WRENCH IN POSITION.
TW4000
2. Insert the 5/8" socket and
ratchet handle so that it com-
pletely engages with the
drive shaft.
Turn the drive
shaft in the counterclock-
wise direction only.
(See
Fig. 2)
WARNING: KEEP THE
CLUTCH KNOB IN THE
“ENGAGED”
POSITION
WHILE CRANKING WINCH.
DO NOT PUT CLUTCH IN
“FREE WHEEL.”
TW9000
2. Insert the emergency handle so it completely engages
with the drive shaft. Pull in strap by turning the handle
in the clockwise direction (See Fig. 2A). To make
cranking easier, the clutch handle can be placed in the
“free wheel” position while holding onto the emer-
gency crank handle.
WARNING: IF THE CLUTCH IS PLACED IN FREE
WHEEL FOR HAND CRANKING, BE SURE TO
MAINTAIN A FIRM GRIP ON THE HANDLE AT ALL
TIMES.
Because the TW9000 emergency crank handle
attaches to the clutch side of
the winch, it is equipped with
a spring-operated clip which
will be depressed by the
clutch handle in the free
wheel position when crank-
ing in a clockwise direction to
retrieve strap. This clip is a
safety feature and will re-
enage the clutch mechanism
in the event the operator
loses control of the handle
with a load on the winch.
WARNING: EVEN WITH
THIS SAFETY FEATURE, THE HANDLE WILL SPIN
VIOLENTLY ONE OR TWO TURNS BEFORE RE-
ENGAGING THE CLUTCH TO STOP THE WINCH.
DO NOT LOSE CONTROL.
3. Always remove the handle from the winch after use
and replace the plastic plug.
For long life and trouble-free operation your winch
should periodically be inspected for any required mainte-
nance. This should be done at least once annually and
more frequently in adverse conditions such as salt water
areas or areas of extreme dust and dirt.
WARNING: BEFORE PERFORMING ANY MAINTE-
NANCE BE SURE THERE IS NO LOAD ON THE
WINCH AND THAT THE POWER HAS BEEN
DISCONNECTED.
1. Carefully inspect the winch strap and replace at the
first sign of damage. In order to replace the winch
strap, it is necessary to remove the winch cover. On
the TW4000, remove the slotted nut in the end of the
knob with a screwdriver and unscrew the knob from
clutch stud. Remove the nut holding the toggle switch
into the cover and push the switch inside the winch.
Remove the six cover screws and lift the cover from
the winch while gently stretching it open to clear the
clutch stud. On the TW9000, remove the clutch handle
by removing the two clutch handle screws and then
remove the six cover screws. Lift the cover from the
winch while gently stretching it open to clear the clutch
stud.
Rotate the winch reel to gain access to the strap bolt.
Remove the old strap and replace it with a new strap
of the same size. If the strap bolt is bent, replace it
with a bolt of the same size and length. Note that nut
on the strap bolt must be on gear side of winch reel
and locknut must be used. Do not substitute free run-
ning nut. Slide bolt to bottom of slot and tighten nut
until snug. Do not over tighten, strap will hold bolt in
bottom of slot.
NOTE: STRAP IS WOUND OVER THE TOP OF THE
DRUM ON MODEL TW4000 AND UNDER THE
DRUM ON MODEL TW9000.
2. With the cover removed as described above, inspect
the entire gear train and all drive shafts for any signifi-
cant wear or loose bearing fits. Also, check all nuts,
bolts, retaining rings, etc., to be sure that they are tight
and secure. Grease all of the gears on the inside of
the winch base and apply a drop of oil on all of the
bearings in the base. Also, very sparingly oil all of the
WINCH MAINTENANCE
AUXILIARY HANDLE
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Socket & Ratchet
Handle Illustration
(TW4000)
FIG. 2
Emergency Handle
Illustration (TW9000)
FIG. 2A
