Kolpin 25-9250 Owner'S And Operator'S Manual Download

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2017 Kolpin Outdoors Inc.

REV 02

2500 lb / 3500 lb / 4500 lb

ATV / UTV WINCH KIT

P/Ns: 25

9250, 25

9255, 25

9350, 25

9355, 25

9450, 25

9455

OWNER’S / OPERATING INSTRUCTIONS / SPARE PARTS

Application

WINCH MOUNT NO. 25

XXXX, OEM VEHICLE WINCH MOUNTS

Before you begin, please read these instructions and check to be sure all parts and tools are

accounted for. The following instructions contain details required to operate, install and service the

contents of this kit. Save these instructions. Important safety instructions are included in this manual.

Summary of Contents for 25-9250

Page 1: ...E PARTS Application WINCH MOUNT NO 25 XXXX OEM VEHICLE WINCH MOUNTS Before you begin please read these instructions and check to be sure all parts and tools are accounted for The following instructions contain details required to operate install and service the contents of this kit Save these instructions Important safety instructions are included in this manual ...

Page 2: ... the remote switch optional 7 Wiring the winch 7 Winch Wiring diagram 8 Corded Remote and Rocker Switch Wiring Diagram 9 ATV UTV Winch User Guide 10 Winch Safety Precautions 10 11 Winch Operation 12 14 Wire Cable Care 14 Shock loading 15 Winch Maintenance and Service Safety 16 Lubrication 16 Cable Assembly Replacement 16 Specifications 17 Performance Specifications 17 Parts Kit Diagrams and replac...

Page 3: ... 1 877 956 5746 Part Number Date of Purchase Purchase Location GUIDEBOOK CONVENTIONS This manual uses the following symbols to help differentiate between different kinds of information The safety symbol is used with a signal word to alert you to potential hazards in operating and owning power equipment Follow all safety messages to avoid or reduce the risk of serious injury or death Each message h...

Page 4: ... In locks the winch into the gear system 6 Mount Assembly Flatbed mounting channel 7 Roller Fairlead When using the winch at an angle the roller fairlead acts to guide the wire rope onto the drum and minimizes damage to the wire rope from abrasion on the winch mount or bumper 8 Rubber Winch Stop Increases life of cables ropes and fairleads Quiets hook rattling noise 9 Rope Galvanized steel aircraf...

Page 5: ...l for specific installation instructions See Kolpin com for a full assortment of custom winch mounts for ATV UTVs Mount the winch to the mount plate not included as shown below Rotate the lock knob to the free spool position and feed the winch cable through the rollers of the roller fairlead Mount the roller fairlead plate and attach the hook clevis and nylon pull strap Rotate the lock knob back t...

Page 6: ... MOUNTING THE CONTACTOR SOLENOID The contactor solenoid is a primary safety feature in the winch system It disconnects the winch from its power source when the vehicle is not in use The contactor solenoid must be correctly installed to work properly Find a location for the contactor solenoid It is recommended that the contactor solenoid be mounted close to the battery in a clean dry location The e...

Page 7: ...Avoid crossing cables over each other for at least the first 6 of cable starting from the contactor solenoid post Tighten the contactor solenoid terminal nuts DO NOT over tighten Seat terminal boots over ring terminals and posts Connect the rocker switch to the contactor solenoid using the provided plug Splice the end of the red wire on the rocker switch to a vehicle accessory circuit controlled b...

Page 8: ...ls Attach to yellow terminals Contactor solenoid Attach to positive battery terminal Attach to negative battery terminal Switch harness Use wire splice connector to splice switch harness red wire to a key controlled accessory circuit wire on the vehicle Connect to switch harness ...

Page 9: ...rded Remote Switch Corded remote male socket Rocker Switch Use wire splice connector to splice switch harness red wire to a key controlled accessory circuit wire on the vehicle Connect contactor male connector to remote socket female connector Connect rocker switch female connector to remote socket male connector Inline Fuse for remote power ...

Page 10: ...he winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load 10 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed 11 Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the win...

Page 11: ...e the winch to hoist or suspend a vertical load 21 Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs 22 Always inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch components 24 Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent...

Page 12: ...ay particular attention to the first three feet one meter of the winch cable if the winch is being used or has been used for lifting an accessory plow assembly Promptly replace any worn or damaged cable 2 Never operate a winch or a vehicle in need of repair or service 3 Always apply your vehicle s parking brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if ...

Page 13: ...so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper D Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation 9 Never hook the winch cable back onto itself This will damage the winch cable ...

Page 14: ... winch cable wedging itself between lower layers of winch cable WINCH CABLE CARE For your safety always replace KOLPIN winch parts including the cable with KOLPIN replacement parts available at your authorized KOLPIN dealer or the KOLPIN website Kolpin com 1 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs r...

Page 15: ...y of the vehicle and possibly lead to an accident 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous Similarly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportati...

Page 16: ...for winch use will stretch and store excessive energy when winching LUBRICATION All moving parts within the electric winch have been lubricated using high temperature grease at the factory No internal lubrication is required Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable CABLE ASSEMBLY REPLACEMENT It is recommended that...

Page 17: ... Motor duty cycle Intermittent Gear reduction ratio 166 1 Brake Mechanical Electric cable leads 8 gauge 2500 lb 3500 lb 6 gauge 4500 lb Winch cable size 50 length x 3 16 diameter wire rope 3 16 diameter synthetic model 2500 lb rated pull 50 length x 7 32 diameter wire rope 3 16 diameter synthetic model 3500 lb rated pull 50 length x 7 32 diameter wire rope 1 4 diameter synthetic model 4500 lb rate...

Page 18: ...at washer M4 9 1 Scotch lock 10 6 Cable tie 8 11 2 Hex nut M4 12 8 Flat washer M8 13 4 Hex nut M8 x 1 25 14 4 Lock washer M8 15 6 Hex bolt M8 x 1 25 x 25mm zinc plated 16 2 Hex bolt M8 x 1 25 x 20mm zinc plated 17 6 Terminal cap RPR0109 18 1 Clevis hook RPR0108 19 1 Cable red 8 gauge 36 RPR0119A 20 1 Cable black 8 gauge 36 RPR0120A 21 1 Cable yellow 8 gauge 96 22 1 Cable blue 8 gauge 96 23 1 Unive...

Page 19: ...4 9 1 Scotch lock 10 6 Cable tie 8 11 2 Hex nut M4 12 8 Flat washer M8 13 4 Hex nut M8 x 1 25 14 4 Lock washer M8 15 6 Hex bolt M8 x 1 25 x 25mm zinc plated 16 2 Hex bolt M8 x 1 25 x 20mm zinc plated 17 6 Terminal cap RPR0109 18 1 Clevis hook RPR0108 19 1 Cable red 8 gauge 36 RPR0119A 20 1 Cable black 8 gauge 36 RPR0120A 21 1 Cable yellow 8 gauge 96 22 1 Cable blue 8 gauge 96 23 1 Winch Stop 85080...

Page 20: ...Scotch lock 10 6 Cable tie 8 11 2 Hex nut M4 12 8 Flat washer M8 13 4 Hex nut M8 x 1 25 14 4 Lock washer M8 15 6 Hex bolt M8 x 1 25 x 25mm zinc plated 16 2 Hex bolt M8 x 1 25 x 20mm zinc plated 17 6 Terminal cap RPR0109 18 1 Clevis hook RPR0108 19 1 Cable red 8 gauge 36 RPR0119A 20 1 Cable black 8 gauge 36 RPR0120A 21 1 Cable yellow 8 gauge 96 22 1 Cable blue 8 gauge 96 24 1 Universal Fairlead Mou...

Page 21: ...10 6 Cable tie 8 11 2 Hex nut M4 12 8 Flat washer M8 13 4 Hex nut M8 x 1 25 14 4 Lock washer M8 15 6 Hex bolt M8 x 1 25 x 25mm zinc plated 16 2 Hex bolt M8 x 1 25 x 20mm zinc plated 17 6 Terminal cap RPR0109 18 1 Clevis hook RPR0108 19 1 Cable red 8 gauge 36 RPR0119A 20 1 Cable black 8 gauge 36 RPR0120A 21 1 Cable yellow 8 gauge 96 22 1 Cable blue 8 gauge 96 23 1 Winch Stop 85080 24 1 Corded Remot...

Page 22: ...Cable tie 8 11 2 Hex nut M4 12 8 Flat washer M8 13 4 Hex nut M8 x 1 25 14 4 Lock washer M8 15 6 Hex bolt M8 x 1 25 x 25mm zinc plated 16 2 Hex bolt M8 x 1 25 x 20mm zinc plated 17 6 Terminal cap RPR0109 18 1 Clevis hook RPR0108 19 1 Cable red 6 gauge 36 RPR0119A 20 1 Cable black 6 gauge 36 RPR0120A 21 1 Cable yellow 6 gauge 96 22 1 Cable blue 6 gauge 96 23 1 Corded Remote Switch 85067 24 1 Dash Mo...

Page 23: ... 11 2 Hex nut M4 12 8 Flat washer M8 13 4 Hex nut M8 x 1 25 14 4 Lock washer M8 15 6 Hex bolt M8 x 1 25 x 25mm zinc plated 17 6 Terminal cap RPR0109 18 1 Clevis hook RPR0108 19 1 Cable red 6 gauge 36 RPR0119A 20 1 Cable black 6 gauge 36 RPR0120A 21 1 Cable yellow 6 gauge 96 22 1 Cable blue 6 gauge 96 16 2 Hex bolt M8 x 1 25 x 20mm zinc plated 23 1 Winch Stop 85080 24 1 Corded Remote Switch 85067 2...

Page 24: ...tch freespool knob not engaged Move freespool knob to the locked spool position If problem persists a qualified technician needs to check and repair Motor runs slowly or without normal power Insufficient current or voltage The battery is weak recharge Run winch with vehicle motor running battery should have a strong charge Loose or corroded battery cable connections Clean tighten or replace Motor ...

Page 25: ...all 1 877 956 5746 for a Return Merchandise Authorization RMA number and shipping instructions This warranty does not apply to parts that have been damaged by accident alteration abuse improper maintenance normal wear or other causes beyond the manufacturer s control In order to protect you and your ATV certain parts of the winch plow system and or hardware are designed to fail when the equipment ...

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