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2.SPECIFIC OPERATION WARNING

General Safety

    1.To prevent injury or property damage, read and understand all instructions 

before operating winch.
    2.Wear ANSI Z87.1 compliant safety goggles and heavy duty leather work 

gloves during operation.
    3.Do not exceed the rated load capacity. Be aware of dynamic loading! Sudden 

load movement may briefly create excess load causing product failure.

Installation Safety

    1.Choose a mounting location that can support the winch and rated load 

capacity.

    2.Do not weld mounting bolts. 

    3.Use supplied power cords and wire rope listed in manual only. Do not use 

thinner/longer cablesor link multiple cables together.

    4.Keep hands clear of winch rope, hook loop, hook and fairlead opening during 

installation, operation, and when spooling in or out.

    5.Wrap the wire rope under 500 lbs. of tension before use. Otherwise, the wire 

rope may bind during operation.
    6.Do not route electrical cables near sharp edges or parts that will move or 

become hot. 

    7.Ventilate area well before and while working on battery. Explosive hydrogen 

gas can accumulate and explode when ignited by a spark or open flame.

    8.Only connect to a clean, corrosion free battery.

    9.Remove all jewelry and metallic objects before working near battery.

Winching Safety

    1.Inspect winch rope, hook, and slings before operating winch. Frayed, kinked 

or damaged winch rope must be replaced immediately. Damaged components 

must be replaced before operation.

    2.Do not maintain power to the winch if the motor stalls. Verify the load is 

within the rated capacity for the wire rope layer. Make sure the battery is fully 

charged. Use double line rigging whenever possible.
    3.Do not engage or disengage clutch while under load.  
    4.Always ensure hook latch is closed and not supporting load.
    5.Never apply load to hook tip or latch. Apply load only to the center of hook.

    6.Never use a hook whose throat opening has increased, or whose top is bent 

or twisted.

    7.Keep clear of fairlead when operating. Do not try to guide wire rope.

    8.Do not place any fingers through the hook. Fingers may be caught and get 

pulled into the fairlead or drum. Use the included strap to hold the hook instead.

 3

Содержание 2500LB

Страница 1: ...ZEAK 2500LB WINCH ...

Страница 2: ...ATION INSTRUCTIONS before operating Failure to follow the safety rules and other basic safety precautions may result in serious personal injury Keep this manual and the receipt in a safe and dry place for future reference ZEAK 2500LB Electric ATV WINCH 12 Volt ...

Страница 3: ...Work Area Safety 1 Personal Safety 2 2 General Safety 3 3 3 Installation Safety 5 Winching Safety Mounting the Solenoid Assembly 7 Circuit Break Protection Rubber Sleeve 9 Clutch Operation 10 Operation Warning 11 6 TROUBLESHOOTING 14 7 MAINTENANCE 15 8 PARTS DIAGRAM 16 9 REPLACEMENT PART 17 Duty Cycle 13 Wiring 8 4 ASSEMBLY INSTRUCTIONS Mounting the Winch 7 Hazardous Chemicals Warning 1 ...

Страница 4: ...nditions or situations that could occur Exercise common sense and caution when using this electric winch Always be aware of the environment and ensure that the electric winch is used in a safe and responsible manner Do not modify this electric winch in any way Unauthorized modification may impair the function and or safety and could affect the life of the electric winch There are specific applicat...

Страница 5: ...he work area Inspect before every use do not use if damaged or parts loose Examine the winch for structural cracks bends damage frayed or kinked wire rope and any other conditions that may affect the safe operate of the winch Do not use the winch even if minor damage appears A kink permanently weakens the wire rope even after it is straightened out kinked wire rope can fail suddenly and must not b...

Страница 6: ...ntilate area well before and while working on battery Explosive hydrogen gas can accumulate and explode when ignited by a spark or open flame 8 Only connect to a clean corrosion free battery 9 Remove all jewelry and metallic objects before working near battery Winching Safety 1 Inspect winch rope hook and slings before operating winch Frayed kinked or damaged winch rope must be replaced immediatel...

Страница 7: ...n the drum 22 Keep clear of the wire rope hook and load while winching Do not step over the wire rope Do not push sideways against the wire rope under tension wire rope might break under this load and recoil back striking the person pushing against it or a bystander 23 If the wire rope begins to get entangled stop the winch immediately and release the wire rope using the switch 24 Only winch with ...

Страница 8: ...tion to any off road adventure Technical Specifications 5 Layer Wire Rope Capacity Rated Line Pull First layer of Wire Rope Performance 2 1 3 4 5 6 2500lb 1134kg 6 1 8m 2045lb 928kg 13 3 4 0m 1731lb 785kg 21 9 6 7m 1500lb 680kg 31 8 9 7m 1324lb 600kg 43 1 13 1m 1184lb 537kg 50 15 2m Line Pull lb Amp Draw 12v Line Speed fpm mpm 1 0 13 3 4 1 10 1000 8 3 2 5 55 2000 4 1 1 2 106 2500 2 7 0 8 132 ...

Страница 9: ...DC Battery Cables 10 Gauge 5 8 long Solenoid Cables 10 Gauge 1 3 long Solenoid Solenoid Weather sealed Mounting Bolt Pattern 3 15 80mm 3x G8 Winch M8 1 25X35mm 2x G8 Fairlead M8 1 25 X19mm Warranty one year Mounting Hardware Rope Material Synthetic Rope Length ft 50 Rope Diameter in 3 16 Sound Rating 85dB Dimensions 11 7 x3 97 x4 13 Weight 13 55 lb IP Rating IP 65 Duty Cycle Rating 5 45 Sec at Max...

Страница 10: ...o weld on additional brac ing depending on the mounting location 4 Drill holes appropriate for the hardware at the marked locations 5 Install the winch using hardware described under Specifications Mounting the Solenoid Assembly 1 Mount the solenoid box in proper location so that a The winch components are close enough to each other to allow wires to be routed properly b The vehicle component oper...

Страница 11: ...omponents which may create damage to 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 above See t...

Страница 12: ...ect for 5 full wraps 3 Recoil the rope back into the winch under at least 500lb of tension Circuit Break Protection Rubber Sleeve 9 How to Use It You only need to heat it evenly with a hot air blower or a candle to make it shrink they can be used for circuit break protection group of lines marking resistance electric capacity reason protection ...

Страница 13: ...ic objects before working near battery Warning 1 Read the entire Important Safety Information section at the beginning of this winch 2 The instructions that follow are basic guidelines only and cannot cover all situations encountered during use The operator and assistants must carefully plan usage to prevent accidents Clutch Operation 1 The position of the pin in the shaft determines whether the c...

Страница 14: ...ncy brake and block the wheels using wheel chocks sold separately 6 Hook onto the object using a pulling point tow strap tree strap or chain See the following picture 8 Do not use a recovery strap while winching They are designed to stretch and can suddenly whip back towards the operator during a winching operation 9 Place a heavy rag or carpet sold separately over the wire rope span 6 feet from t...

Страница 15: ... Do not power the hook all the way into the fairlead to prevent damage 14 Do not operate the winch at extreme angles Do not exceed the angles shown below for a roller fairlead For a hawse fairlead the angle should be as close to straight as possible 15 If the object to be pulled must be pulled at an angle in relation to the winch use a pulley sold separately and an anchor point directly in front o...

Страница 16: ...the hook from the load and reel in the wire rope 19 Disconnect the pendant controller if equipped after use Duty Cycle Avoid damage to the winch by not winching for more than the prescribed duty cycle time The duty cycle defines the amount of time within a 15 minutes period during which a winch can operate at its maximum capacity without overheating For example this winch with a 5 duty cycle at it...

Страница 17: ...le connections 3 Fully charge battery 4 Tap solenoid to loosen contacts Apply 12 volts to coil terminals directly A clicking indicates proper activation 5 Replace remote 6 Check for voltage at armature port with switch pressed If voltage is present replace motor 7 Allow to drain and dry Run in short bursts without load until completely dry 8 Have technician service winch Motor runs but wire rope d...

Страница 18: ...ury from winch failure do not use damaged equipment If an abnormal noise or vibration occurs have the problem corrected before further use 4 Lubricate the wire rope occasionally corrected before further use 5 The winch s internal mechanism is a permanently lubricated Do not open the housing However if the winch is submerged it should be opened dried and re lu bricated by a qualified technician as ...

Страница 19: ...ushing Pan Head Screw M4X 12MM Drum Support Plate Rotator Gear Gear Ring Planetary Gear Assembly Motor Winch Mounting Hardware Hawse Fairlead Fairlead Mounting Hardware Hook Red Strap Pendant Controller Control Box Circuit Breaker Parts List Part Number Description Quantity Clutch Knob 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 4 1 2 2 2 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 23 24 25...

Страница 20: ...lustrations provide are a convenient reference to the location and position of parts in the assembly sequence When ordering parts the following information will be required item descrip tion item model number item serial number item lot date code and the replace ment part number 17 ...

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