Trailmaxx WA Series Einrichtungshandbuch

WA Series

Electric Winch

3500lb

Installation and operator’s manual

SAFETY PRECAUTIONS

Warning! Observe safety precautions for personal safety and the safety of others. Improper equipment operation

may cause personal injury and equipment damage.

Read the following carefully before attempting to operate your winch and keep the instructions for future

reference.

1. Dress properly:

Do not wear loose clothing or jewellery; they can be caught in moving parts.

Wear leather gloves when handling winch cable, as broken wires can cause injuries.

Non-slip footwear is recommended.

2. Keep a safe distance:

Ensure that all persons stand well clear of the winch cable and load during winch operation, 1.5

times the cable length is recommended. If a cable pulls loose under load or breaks it can lash

back and cause serious injury.

Do not step over the cable

All visitors and onlookers should be kept well clear of the work area.

Ensure a secure footing and balance while operating the winch.

3. Do not misuse the control cable:

Never carry the winch by the cord, or disconnect it from the receptacle by pulling the cable.

Keep cable away from heat, oil and sharp edges.

4. Do not overwork the winch:

If the motor becomes uncomfortably hot to touch, stop and let it cool for a few minutes.

Do not maintain power to the winch if the motor stalls.

Do not exceed maximum line pull ratings shown in tables, shock loads must not exceed these

ratings.

Any winch showing signs of misuse and/or excessive heat will not be accepted for warranty.

5. Avoid unintentional starting:

Winch clutch should be disengaged when not in use and fully engaged when in use.

Never release the winch clutch while under load.

6. Check for damaged parts:

Before using, you should check your winch carefully. Any part that is damaged should be properly

repaired or replaced by a Trailmaxx authorised service centre.

7. Repairing your winch:

When repairing the winch use only genuine Trailmaxx replacement parts, as using any other

parts will invalidate the warranty and may result in injury to the user.

8. Re-spooling the cable:

Leather gloves must be worn while re-spooling.

To re-spool correctly, it is necessary to keep a slight load on the cable. Hold the cable with one

hand and the remote control switch with the other. Start as far back and in the centre as you can.

Walk up, keeping load on the cable as the winch is powered in.

Do not allow the cable to run loosely through your hand and do not approach the winch too

closely.

Turn off the winch and repeat the procedure until all but 1m of cable is in.

Disconnect the remote control switch and finish spooling in the cable by rotating the drum by

hand with the clutch disengaged.

On hidden winches, spool in the cable under power but keep hands clear.

WINCH OPERATION WARNINGS

Read the following carefully before attempting to operate your Trailmaxx winch and keep the instructions for

future reference.

1. The uneven spooling of cable while pulling a load is not a problem, unless there is a cable pile up at one

end of the drum. If this happens reverse the winch to relieve the load and move your anchor point further

to the centre of the vehicle. After the job is done you can unspool and rewind for a neat lay of cable.

2. Store the remote control switch inside your vehicle where it will not be damaged, and always inspect it

before you plug it in.

3. When ready to begin spooling in, plug in the remote control switch with clutch disengaged. Do not engage

the clutch with the motor running.

4. Never connect the hook back to the cable as this causes cable damage. Always use a sling or chain of

suitable length.

5. Keep a close watch on your winch from a safe distance while operating; stop the winch periodically to

check that the cable is not pulling up in a corner. Jamming the cable can break your winch.

6. Do not attach tow hook to winch mounting plate, it must be attached to the vehicle frame.

7. The use of a snatch block will aid recovery operations by providing a doubling of the winch capacity and a

halving of the winch speed, and the means to maintain a direct line pull to the centre of the rollers. When

double loading during stationery winching, the winch tow hook should be attached to the chassis of the

vehicle.

8. Ensure rated “D” or bow shackles are used in conjunction with an approved tree trunk protector to

provide a safe anchor point.

9. When extending the winch cable, ensure that the cable is wrapped at least 5 times around the drum at all

times. Failure to ensure this could result in the cable parting from the drum under load resulting in severe

personal injury and/or damage to property.

10. All Trailmaxx winches are provided with a marking on the cable to indicate when the last 5 turns of cable

are left on the drum. No recovery should be attempted with this mark showing beyond the rollers.

11. Since the greatest pulling power is achieved on the innermost layer of your winch, it is desirable to pull off

as much line as possible for heavy pulls (You must leave at least 5 turns on the drum). If this is not

practical use a snatch block and double line arrangement.

12. Draping a heavy blanket or similar object over the extended winch cable is recommended as it will

dampen any backlash should a failure occur.

13. Neat, tight spooling avoids cable binding, which is caused when a load is applied and the cable is pinched

between the other coils. If this happens, alternatively power the winch in and out; do not attempt to work

a bound cable under load, free by hand.

14. Apply blocks to wheels when vehicles are on an incline.

15. Battery:

Be sure that the battery is in good condition. Avoid contact with the battery acid and other

contaminants.

Always wear eye protection when working around a battery.

Have the engine running when using the winch to avoid draining the battery.

16. Winch cable:

Be sure that the cable is in good condition and is attached properly.

Do not use the winch if cable is frayed.

Do not move the vehicle to pull a load.

Do not replace the cable with a cable of lesser strength.

The life of the cable is directly related to the use and care it receives. Following its first and

subsequent uses, a cable must be wound on to the drum under a load of at least 500lbs (230kgs)

or the outer wraps will draw into the inner wraps and severely damage the cable during

winching. The first winch run should be a familiarisation run while in a relaxed, non-recovery

situation. Spool out the cable until the cable mark appears, then rewind the cable on the drum

under a load of 500lbs (230kgs) or more. This will slightly stretch and tension the new cable and

create a tight cable wrap around the drum. Failure to do so may result in cable damage and

reduced cable life.

When the cable is replaced, be sure to apply loctite or an equal compound to the cable clamp

thread. Tighten the clamp screw properly but do not over tighten. The loctite will prevent

loosening of the screw in arduous conditions. Loctite 7471 primer and 222 threadlocker are

recommended.

17. Do not attempt to exceed the pulling limits of this winch

18. Do not drive your vehicle to assist the winch in any way. Vehicle movement in combination with winch

operation may overload the cable, the winch itself or cause damaging shock loads.

19. Shock loads when winching are dangerous! A shock load occurs when an increase in force is suddenly

applied to the cable. A vehicle rolling back on a slack cable may induce a damaging shock load.

20. The winches shown in this manual are solely for vehicle and boat mounted non-industrial applications.

21. Do not use the winch in hoisting as these winches do not conform to the required hoist safety factors and

features.

22. Do not use the winch to lift, support or otherwise transport personnel.

INSTALLATION

Mounting your winch

Mount the winch on the vehicle using the M8 x 30 bolts and spring washers provided. The winch must be mounted

in position with the cable spooling off the bottom of the reel not the top. Improper mounting could damage your

winch and void the Trailmaxx warranty.

Lubrication Installation

All moving parts in the winch are permanently lubricated with high temperature lithium grease at time of

assembly. Lubricate cable periodically using light penetrating oil. Inspect cable for broken strands regularly and

replace if necessary. If the cable becomes worn or damaged it must be replaced. Do not replace cable with a cable

which is rated lower than the original.

Electrical connection

For normal self recovery work, your existing electrical system is adequate. A fully charged battery and proper

connections are essential. Run the vehicle engine during winching operations to keep the battery fully charged.

1.1. Connect the red motor terminal to the red motor connection terminal on the control box using a red

cable.

1.2. Connect the black or white motor terminal to the black motor connection terminal on the control box

using a black cable.

1.3. Connect the red power cord terminal on the control box to the positive (+) terminal on the battery using

a red cable.

1.4. Connect the black power cord terminal on the control box to the negative (-) terminal on the battery

using a black cable.

1.5. Check the direction of drum rotation. Turn the clutch knob to the “OFF” position and free spool some

cable off the drum. Turn the clutch knob to the “IN” position and push the “IN” button on the controller,

if the cable respools this is correct, if not swop the battery leads over and recheck.

Wireless control

Your Trailmaxx winch is installed with a wireless control unit housed in the control box. This unit should have an

operating range of at least 10 meters. If problems are experienced with the wireless control it may be of benefit to

open the control box, locate the wireless control unit attached to the inside of the case, locate the aerial (green

wire attached only at one end) and feed it out through the bottom of the control box into a more exposed

position. To further extend the performance of the wireless control a Trailmaxx booster aerial can also be fitted.

WINCH OPERATION

Suggestion

The best way to get acquainted with how your winch operates is to make a few test runs before you actually need

to use it. Plan your test in advance. Remember you can hear your winch as well as you can see it operate. Get to

recognise the sound of a light steady pull, a heavy pull, and sounds caused by the load jerking or shifting. Soon you

will gain confidence in operating your winch and its use will become second nature to you.

Operating

1) Ensure the vehicle is secure by applying the park brake or chocking the wheels.

2) Pull out the winch cable to the desired length and connect to the anchor point. The winch clutch allows rapid

uncoiling of the cable for hooking onto the load or the anchor point. The shifter tab located on the gear

housing of the winch operates the clutch as follows:

a) To disengage the clutch, move the clutch shifter tab into the “OUT” position. Cable may not be free

spooled off the drum.

b) To engage the clutch, move the clutch shifter tab into the “IN” position. The winch is now ready for

pulling.

3) Recheck all cable rigging before proceeding.

4) Plug in the winch hand control. It is recommended that the winching operation takes place from the driver’s

position to ensure safe operation.

5) To commence winching operation, start the vehicle engine, select neutral in the transmission, and maintain

engine speed at idle.

6) Operate the remote control switch in or out until the vehicle or load has been retrieved. Regularly check the

winch to ensure cable is winding onto the drum evenly.

Note

1) Never winch with your vehicle in gear as this could damage the transmission.

2) Never wrap the cable around the object and hook onto the cable itself. This can cause damage to the object

being pulled, and may kink or fray the cable.

3) Keep hands, clothing, hair and jewellery clear of the drum area and cable when winching.

4) Never use the winch if the cable is frayed, kinked or damaged.

5) Never allow anyone to stand near the cable or in line with the cable behind the winch while it is under power.

If the cable should slip or brake, it can suddenly whip back towards the winch, causing serious injury to anyone

in the area. Always stand well to the side when winching.

6) Do not leave the switch plugged in while not in use.

CHECK THE WINCH CAREFULLY AND THOROUGHLY BEFORE OPERATING!

Performance specifications

WA35 –12v 3500lb ATV Winch

Performance/Specifications

Single line rated pull

3500lb/1591kg

Gearing

3 stage planetary

Motor

Permanent Magnet 12v DC, 1.1hp

Gear Reduction ratio

136:1

Cable

4.8mm x 15.2m

Clutch

Freespooling, cam activated

Overall Dimensions (mm)

335L x 110W x 112H

Weight

Line Speed and Current Drain - Based on first layer on drum

Line Pull lb/kg

500lb/227kg

1000lb/454kg

2500lb/1134kg

3500lb/1581kg

Line Speed (mpm)

8.3

6.1

4.9

2.1

1.3

Current Drain

160

210

Line Pull Capacity –Based on first layer on drum

Cable Layer

Rated Line Pull per Layer

3500lb/1363kg

2561lb/1164kg

2234lb/1015kg

1981lb/900kg

1779lb/808kg

Total rope on drum

2.7m

5.86m

9.48m

13.58m

15.2m

MAINTENANCE

It is highly recommended that the winch be used regularly (at least once a month). Simply power out the cable

15m, free spool 5m and then power back in. This will keep all components in good working condition so that the

winch can be relied on when needed. Contact your authorised Trailmaxx outlet for technical assistance and

repairs.

NOTE:

The safety precautions and instructions discussed in this manual cannot cover all possible

conditions and situations that may occur. It must be understood by the operator that

common sense and caution are features which cannot be built into this product, and must be

supplied by the operator. accepts no liability for any consequences of using this

product if not used in accord with this manual.

Other quality brands

Call 0800 MAXX11, Email: sales@trailmaxx.co.nz or visit our website

www.trailmaxx.co.nz for more information.

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