Warrior Winches Spartan Series Kurzanleitung

ELECTRICAL WINCH

12000 / 12000-SR

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.

INCLUDED WITH YOUR WINCH

DESCRIPTION QUANTITY

1. Winch Assembly with Wire Rope 1

2. Cap Bolt M10 h35 4

3. Lock Washer Ø10 4

4. Thinck Flat Washer Ø10 4

5. Hex Flange Nut M10 4

CAUTION

WARNING

6. Clevis Hook w/Pin 1

7. Control box of 12000 (Supplied for Prototype) 1

8. Control box of 12000-S (Supplied for –S Type) 1

9. Power Switch supplied by your choice

9.1 üR1, Remote control 1

9.2 üR2, Remote control 1

9.3 üR3, Remote control 1

9.4 Wireless Remote Control 1

THE FOLLOWING DESCRIPTIONS ARE OPTIONAL

001. Snatch Block/Pulley 1

002. Roller Fairlead and Screws 1

003. Mounting Channel 1

004. SWR Tensioner 1

WINCH ACCESSORIES YOU WILL NEED

NOT INCLUDED WITH YOUR WINCH Gloves

–For handling the wire rope and hook strap.

Anchor Strap/Chain –Tree saver anchor straps are made of high quality nylon with high

tensile strengths up to 15000lbs.

Heavy Blanket –place on the cable to absorb energy should the wire rope break.

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:

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,

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 BoltM10 X 35 (Part# 120002), FlatWasher

(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 12ąof the winch while respooling. 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

Fig 3.1

Do not winch from an acute angleas 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

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.

Fig 3.2

Fig 3.3

Fig 3.4

Fig 3.5

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