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Item 56528
SAFEty
OPERA
tiOn
MAintEnAnCE
SEtuP
Wiring
tO PREVEnt SERiOuS inJuRy FROM EXPLOSiOn
DuE tO SPARKinG At tHE BAttERy COnnECtiOn:
Disconnect the Battery Cables before making other wiring connections.
tO PREVEnt SERiOuS inJuRy FROM LEAKinG BAttERy ACiD:
Do not use a dirty, corroded or leaking battery.
Only use a 12V automotive (or equivalent) battery, in good condition.
1. Plan a route for the wiring from the point of
the vehicle where the Winch will be mounted,
or used, to the battery. This route must be
secure, out of the way of moving parts, road
debris, or any possibility of being damaged by
operation or maintenance of the vehicle. For
example, you may wish to route the wires under
the vehicle, attaching it to the frame using
suitable fasteners. Do not attach the wires to
the exhaust system, drive shaft, emergency
brake cable, fuel line, or any other components
which may create damage the wiring through
heat or motion, or create a fire hazard.
2. If you drill through the bumper or any part
of the body to route the wires, be sure
to install a rubber grommet in the hole to
prevent fraying of the wires at that point.
3. Route the Cables from the Solenoid to the battery
and from the Solenoid to the Winch, following the
precautions discussed earlier. Refer to Figure E.
Battery
Red
(to ignition)
Circuit
Breaker
Solenoid
Winch
Blue
Blue
Black
Black
Red
yellow
Figure E: Wiring Connections
4. Attach the wires from the Solenoid
to the terminals on the Winch.
5. Attach the Circuit Breaker to the Positive
Terminal on the battery and to the Solenoid.
6. Attach the black Battery Cable directly to
the negative terminal of the battery.
7. Wire in the Socket Lead and connect the
Remote Control and Handlebar Switch
according to the diagrams on this page.
8. Connect the red wire from the Socket Lead
to an ignition circuit (switched by the vehicle′s key).
the Winch will not operate if that
wire is not properly connected.
a. Use a circuit tester to find a wire that energizes
when the vehicle′s key is turned to on, and
turns off when the key is turned to off.
b. That is an ignition controlled wire.
c. Connect wire shown in Figure F to that wire.
Red
(to ignition)
Socket Lead
Figure F:
Wiring to vehicle′s keyed ignition
note: if not attaching the Winch to a vehicle, attach
the ignition wire to the positive battery terminal.
iF tHiS iS nOt DOnE, tHE WinCH
WiLL nOt OPERAtE.
9. After the unit is connected, operate the remote
controls briefly to test Winch function and Drum
rotation direction. If operation is reversed, the
Battery Cables may be connected backwards.
Correct any such issue before use.
Preparing the Wire Rope
1. The Wire Rope must be properly coiled under
tension to be able to support a load without damage.
2. Uncoil the Wire Rope, except for 5 full wraps.
3. Recoil the Wire Rope back into the Winch
under at least 500 lb. of tension.
