DK2 Warrior Spartan 1200 Kurzanleitung

ELECTRICAL WINCH

12SPS12

12SPS24

Assembly & Operating Instructions

INTRODUCTION

Congratulations on your purchase of a winch. We design and build winches to strict

specifications and with proper use and maintenance should bring you years of

satisfying service.

WARNING - Read, study and follow all instructions before operating this

device. Failure to heed these instructions may result in personal injury

and/or property damage.

Your winch can develop tremendous pulling forces and if used unsafely or

improperly could result in property damage, serious injury or death. Throughout

this manual you will find the following symbols for caution, warning and danger.

Pay particular attention to the notes preceded by these symbols as they are

written for your safety. Ultimately, safe operation of this device rests with you, the

operator.

Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury. This notation is also used to alert against unsafe

practices.

Indicates a potentially hazardous situation which, if not avoided

could result in death or serious injury.

CAUTION

WARNING

GETTING TO KNOW YOUR WINCH

Your 12000lb winch is a powerful piece of machinery. It is important that

you understand the basics of its operation and specifications so that when

you need to use it, you can use it with confidence and safety. Below is a

list of the components of your winch and their use. Practices using your

winch before you are in a situation to need to use it.

1. Motor: Your 6hp motor is powered by a 12/24 volt battery and provides power

to the gear mechanism which turns the drum and winds the wire rope;

2. Winch Drum: The winch drum is the cylinder on which the wire rope is stored. It

can feed or wind the rope depending on the remote winch switch.

3. Wire Rope: Your winch has a 13/32"X65.6' galvanized aircraft cable designed

specifically for load capacity of 12000lbs. The wire rope feeds onto the drum in

the “under wind” position through the roller fairlead and is looped at the end to

accept the clevis hook pin.

4. 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.

5. Mechanic Gear System: The reduction gears convert the winch motor power

into extreme pulling forces.

6. Braking System: Braking action is automatically applied to the winch drum

when the winch motor is stopped and there is a load on the wire rope. The

braking action is applied by a separate mechanical brake.

7. Free Spooling Clutch: The clutch allows the operator to manually disengage

(“Out”) the spooling drum from the gear train, free spool. Engaging the clutch

(“In”) locks the winch into the gear system.

8. Solenoid: Power from the vehicle battery flows through the weather sealed

switch before being directed to the winch motor.

9. Remote Switch: The Power switch lead has a dual switch for powering in or

powering out your winch drum. The Power switch leads allow you to stand clear

of the wire rope when the winch is under load.

10.Wireless Remote Control: allow you control winch far from 50 Ft away.

11.Universal Flat Bed Mounting Channel: Your winch has been optional supplied

with a flat bed mounting channel that can be mounted to most flat surfaces

such as trailers, step bumpers, truck beds, etc. The mounting channel also has

holes to accept your roller fairlead.

12.Snatch Block: If Your winch were supplied with a snatch block that, used

properly, can double the pulling power of winch, or change your pulling

direction without damaging the wire rope. We recommend you to use double

line and snatch block for pulling over 85% related line pull.

WINCH ASSEMBLY AND MOUNTING

12000lbs:

OUT

1. Your 12000lb winch is designed with a bolt pattern that is standard in this class

of winch. Many winch mounting kits are available that utilize this bolt pattern

for the most popular vehicle and mounting channels. If you cannot find a kit

locally, contact us and we will provide you with the name of a dealer near you.

If you will utilize the mounting channel you must ensure that it is mounted on a

flat surface so that the three major sections (motor, drum and gear housing) are

properly aligned. Proper alignment of the winch will allow even distribution of

the full rated load.

2. Start by connecting the Roller Fairlead (Part# 120700) to the Mounting Channel

(Part# 120025) using 2 each of the Cap Bolt M10 X 35 (Part# 120002), Flat

Washer (Part# 120004), Lock Washer (Part# 120003) and securing with M10

Nut(Part# 120024) (Make sure the bolt is placed through the mounting channel

and roller fairlead from inside the channel. This will allow enough clearance for

the winch to be placed in the channel without obstruction.)

3. Assemble the winch to the Mounting Channel (Part# 120025) by first pulling

and releasing the clutch knob to “Off” position (Free Spooling). Pull out a few

inches of cable from the drum and feed the wire loop through the opening in the

front of the mounting channel and roller fairlead. Now, using the remaining

M10 x 35 Cap Bolts (Part# 120002), Flat Washer (Part# 120004), Lock Washer

(Part# 120003) and M10 Nut (Part# 120005) secure the winch to the mounting

channel.

4. Connect the battery and motor leads as the drawing above every type of winch

is different each other.

5. Connect the winch motor leads as detailed below:

CAUTION – Batteries contain gases which are flammable and explosive.

Wear eye protection during installation and remove all jewelry. Do not lean over

battery while making connections.

6. Assemble the Clevis Hook to the cable. Take off the pin from the Clevis Hook,

connect the Clevis Hook to the cable and mount the pin back to the Clevis

Hook.

7. Always use the Hand Saver when free-spooling and re-spooling the wire rope.

Using the Hand Saver keeps your hands and fingers away from the rotating

drum.

8. Check for proper drum rotation. Pull and turn the clutch knob to the “off”

position (Free-spooling). Pull out some cable from the drum, and then turn the

clutch knob to the “In” position to engage the gears. Press the cable out button

on the power switch. If the drum is turning and releasing more cable then your

connections are accurate. If the drum is turning and collecting more cable then

reverse the leads on the motor. Repeat and check rotation.

SAFETY PRECAUTIONS

WARNING

WARNING – DO NOT EXCEED RATED CAPACITY.

WARNING – Intermittent use only.

WARNING - Do not use winch in lifting or moving or persons.

WARNING - A minimum of five wraps of cable around the drum

barrel is necessary for pulling and holding the rated load. The

cable clamp is not designed to hold the load without 5 wraps of

cable around the barrel.

WARNING - Keep yourself and others a safe distance to the

side of the cable when under tension.

WARNING – The wire rope may break before the motor stalls.

For heavy loads at or near rated capacity, use a pulley

block/snatch block to reduce the load on the wire rope.

WARNING -Never step over a cable, or near a cable under load.

WARNING - Don’t move the vehicle to pull a load (towing) on

the winch cable. This could result in cable breakage.

WARNING-Disconnect the remote control and battery leads

when not in use.

WARNING- Do not exceed maximum pull rating. Avoid “shock

loads” by using the control switch intermittently to take up the

slack in the wire rope. “Shock loads” can far exceed the rate

capacity for the wire rope and drum.

WARNING- Do not exceeds maximum line pull ratings shown

on the tables.

WARNING-When re-spooling the cable, ensure that the cable

spools in the under-wind position with the cable entering the

drum from the bottom, not the top. To re-spool correctly, and

while wearing gloves, keep a slight load on the cable while

pushing the remote button to draw in the cable. Walk toward

the winch not allowing the cable to slide through your hands.

Do not let your hands get within 12

of the winch while re-

spooling. Turn off the winch and repeat the procedure until a

few feet of cable is left. Disconnect the remote control and

finish spooling by hand by rotating the drum by hand with the

clutch disengaged. Keep hands clear of the fairlead and drum

while the winch is under power.

Do not use as a hoist. Do not use for overhead lifting.

Failure to heed these warnings may result in personal injury

and/or property damage.

WARNING - Use gloves to protect hands when handling the

cable. Never let the cable slide through your hands.

WARNING – Never connect the cable back to itself.

Apply blocks to the wheels of the vehicle when on an incline.

No modifications, alterations, or deviation to the winch are

authorized by the manufacturer and SHALL not be made.

Duration of winching pulls should be kept as short as possible. If

the motor becomes uncomfortably hot to the touch, stop

winching immediately and let it cool down for a few minutes. Do

not pull for more than one minute at or near the rated load.

CAUTION - If the motor stalls do not maintain power to the

winch. Electric winches are designed and made of intermittent

use and should not be used in constant duty applications.

CAUTION - Never release the free-spool clutch when there is a load on

the winch.

CAUTION - Use hand saver hook when handling the hook for spooling

or un-spooling the wire rope.

GENERAL TIPS FOR SAFE OPERATION

xThe 12000 and its all derivative types are rated at 12000 lbs

capacity when spooling the first rope layer on the drum. Overloads

can damage the winch/motor/ or wire rope. For loads over 10000

lbs. we recommend the use of the pulley block/snatch block to

double the wire rope line. The will aid in two ways: a) reduce the

number or rope layers on the drum, as well as, b) reduce the load

on the wire rope by as much as 50%. When doubling the line back

to the vehicle, attach to the frame or other load bearing part.

xThe vehicle engine should be kept running during operation of the

winch to minimize battery drain and maximize power and speed of

the winch. If the winch is used for a considerable time with the

engine off the battery may be drained and too weak to restart the

engine

xGet to know your winch before you actually need to use it. We

recommend that you set up a few test runs to familiarize yourself

with rigging techniques, the sounds your winch makes under

various loads, the way the cable spools on the drum, etc.

xInspect the wire rope and equipment before each use. A frayed or

damaged rope shall be replaced immediately. Use only

manufacturer’s identical replacement rope with the exact

specifications.

xInspect the winch installation and bolts to ensure that all bolts are

tight before each operation.

xNever connect the cable back to itself. This will cause cable

damage. Always use a snatch block, sling or chain of suitable

strength as shown in the illustrations.

xStore the remote control inside your vehicle in a place that it will not

be damaged.

xAny winch that appears to be damaged in any way, is found to be

worn, or operates abnormally SHALL BE REMOVED FROM

SERVICE UNTIL REPAIRED. It is recommended that the

necessary repairs be made by a manufacturer’s authorized repair

facility.

xPull only on areas of the vehicle as specified by the vehicle

manufacturer.

xOnly attachments and/or adapters supplied by the manufacturer

shall be used.

RIGGING TECHNIQUES

Self Recovery

Locate a suitable anchor such as a strong tree trunk or boulder.

Always use a sling as an anchor point. CAUTION Do not attach

the clevis hook back onto the cable as this could cause damage to

the cable.

As shown in Fig 3.1

Do not winch from an acute angle as the wire rope will pile up

on one side of the drum causing damage to wire rope and the

winch. Fig 3.2

Short pulls from an angle can be used to straighten the vehicle.

Long pulls should be done with the wire rope at a 90° angle to the

winch/vehicle.

When pulling a heavy load, place a blanket or jacket over the wire

rope five or six feet from the hook. In the event of a broken cable it

will dampen the snap back. For additional protection open the

hood of the vehicle as shown in Fig 3.3

Fig 3.1

Fig 3.2

Fig 3.3

For pulls over 10000lbs, we recommend the use of the snatch

block/pulley block to double line the wire rope. Fig 3.4

This reduces the load on the winch and the strain on the rope by

approximately 50%.

WARNING - Never use your winch for overhead hoisting or

for lifting people or moving people.

WINCHING TECHNIQUES A-Z

a. Take time to asses your situation and plan your pull.

b. Put on gloves to protect your hands.

c. Disengage the clutch to allow free-spooling and also save battery power.

d. Attach the hand saver hook to the clevis hook.

e. Pull out the wire rope to your desired anchor point using the hand saver hook.

f. Secure the clevis hook to the anchor point: Sling, chain or snatch block. Do not

attach the hook back onto the wire rope.

g. Engage the clutch.

h. Connect the remote control to the winch.

i. Start your engine to ensure power is being replenished to the battery.

j. Power in the wire rope guiding the wire under tension to draw up the slack in the

wire. Once the wire is under tension stand well clear. Never step over the wire rope.

k. Double check your anchors and make sure all connections are secure.

l. Inspect the wire rope. Make sure there are at least 5 wraps of wire rope around the

winch drum.

m. Drape a blanket or jacket over the wire rope approximately 5 to 6 feet from the

hook. Open the hood for added protection.

n. Clear the area. Make sure all spectators all well back and that no one is directly in

front or behind the vehicle or anchor point.

o. Begin winching. Be sure that the wire rope is winding evenly and tightly around the

drum. The vehicle that is being winched can be slowly driven to add assistance to the

winching process. Avoid shock loads; keep the wire rope under tension.

Fig 3.4

Fig 3.5

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