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ORIGINAL INSTRUCTIONS

PowerPlant 

Winch

Installation Guide

Every winching situation has the potential for personal injury.  In order to minimize that risk, it is important to read this guide and The Basic Guide to 
Winching Techniques carefully.  Please familiarize yourself with the operation of your winch before using it and be constantly safety oriented.  In this 
guide we provide important safety information and instructions on how to install your winch.  Please read the Basic Guide to Winching Techniques 
for information on how to properly use your winch and proper rigging techniques.

Please keep this manual and other product literature found in this kit for future reference.  In this kit you will find the following pieces of literature:  
Winch Installation Guide, Basic Guide to Winching Techniques, Specification and Performance Data, Product Warranty, Replacement Parts List and 
other product literature specific to some products.

SYMBOL INDEX

SYMBOL

EXPLANATION

Read All Product 
Literature

Always Wear Hearing and 
Eye Protection

Never Use Winch as a 
Hoist

Properly Seat Load in 
Throat of Hook

Wind Rope on Bottom of 
Drum

Finger/Fairlead Crushing 
Hazard

Hand Piercing/Cutting 
Hazard

Explosion/Bursting 
Hazard

Never Route Electrical 
Cables through Sharp 
Edges Hazard

Avoid Installing Electrical 
Cables around Pinch and 
Wear/Abrasion Points

SYMBOL

EXPLANATION

Always Wear Leather 
Gloves

Do Not Move People

Always Use Supplied 
Hook Strap

Never Apply Load to 
Hook Tip or Latch

Never Wind Rope Over 
Top of Drum

Fairlead Pinch Point

Hot Surface Hazard

Fire and Burn Hazard

Never Route Electrical 
Cables through or near 
Moving Parts Hazard

Exposed Wiring Hazard, 
Insulate Exposed Wiring 
and Terminals

Never Hook Back on 
Rope 

Summary of Contents for 91800

Page 1: ...Guide Basic Guide to Winching Techniques Specification and Performance Data Product Warranty Replacement Parts List and other product literature specific to some products SYMBOL INDEX SYMBOL EXPLANATION Read All Product Literature Always Wear Hearing and Eye Protection Never Use Winch as a Hoist Properly Seat Load in Throat of Hook Wind Rope on Bottom of Drum Finger Fairlead Crushing Hazard Hand P...

Page 2: ...ion fairlead with warning readily visible on top Always prestretch rope and respool under load before use Tightly wound rope reduces chances of binding which can damage the rope WARNING WARNING GENERAL SAFETY PRECAUTIONS MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to serious injury or death Winching Safety Always inspect winch rope hook and slings before opera...

Page 3: ... any part of the body or at other people or animals Always turn the compressor off and bleed pressure from the air hose and intercooler before attempting maintenance attaching tools or accessories WARNING RISKTO BREATHING Failure to observe these instructions could lead to serious injury or death Never use air from compressor to supply air for human consumption WARNING GENERAL SAFETY PRECAUTIONS A...

Page 4: ...ode Selector The mode selector allows the user to switch between winching and compressor operation Rope The winch rope s diameter and length are determined by the winch s load capacity and design Wrapped around the winch drum and fed through the fairlead the winch rope is looped at the end to accept the hook s clevis pin Winch Drum The winch drum is the cylinder onto which the winch rope feeds The...

Page 5: ...ly the mounting orientations shown are possible for safe winching operation Refer to the following diagrams for proper mounting orientation All others are improper and inappropriate The mounting details indicate the proper torque levels The use of recommended bolt and lock washer combinations torqued to recommended levels will prevent vibration during operation Specifications listed below Mounting...

Page 6: ...inch when not in use Leaving the remote plugged in may result in a dangerous condition and or battery drain Winch Control Switch The large rocker switch on the remote control handle controls the spooling in and spooling out functions of the winch This switch is operable only when the Mode Selector is in the Winch symbol position MotorTemperature Indicator and Cutoff With heavy usage over a short p...

Page 7: ... quickest and easiest way to spool out winch rope Before freespooling winch rope out from the winch power out enough rope to remove any tension the winch rope might be under Disengage the clutch Then freespool by manually spooling out enough winch rope for the winching operation See The Basic Guide to Winching Techniques for more information NOTICE DoNOTpoweroutmorethan30ftwithoutallowing thewinch...

Page 8: ...cle to operate Instruct your assistant to stand to the side of the vehicle and away from the winch rope Your assistant should signal you if the winch rope is winding correctly by watching it move across the fairlead as the winch rope is powered in Start the vehicle and place the transmission in neutral Release the parking brake while applying moderate brake pedal pressure Press power in on the rem...

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