4WD WINCHUSER GUIDE

4WD ACCESSORIES

YEAR WARRANTY

1AFTER SALES SUPPORTwww.4x4tough.com.ausales@4x4tough.com.au1300 883 104

MODEL: 21-280467 09/21

AUS

W2705989

V1.0 21st June, 2021 Original Release

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WINCH OPERATION WARNINGS ...................................................................... 6 - 7

SYMBOL INDEX 7

12V DC 4WD WINCH PARTS LIST ...........................................................................8

......................................................... 9

12V DC 4WD WINCH KIT 10

INSTALLATION .......................................................................................................11

12OPERATION

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11

5443 kg /12000 Lb LINE PULL AND CABLE CAPACITY TABLE ........................13

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14

BATTERY REPLACEMENT ....................................................................................14

RECEIVER COMPONENT REPLACEMENT ..........................................................14

MAINTENANCE & STORAGE ................................................................................15

DISPOSAL ...............................................................................................................15

F A Q ........................................................................................................................15

TROUBLESHOOTING ................................................................................................16

12V DC 4WD WINCH PARTS LIST DIAGRAM

WINCHING PRINCIPLES

REMOTE HAND CONTROL OPERATIONS

2

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13

Contents

SPECIFICATIONS

ELECTRICAL CONNECTION

Page

WARRANTY DETAILS ..............................................................................................3

REPAIR AND REFURBISHED GOODS OR PARTS NOTICE ..................................3

WELCOME ...............................................................................................................4

SAFETY PRECAUTIONS ......................................................................................... 5

AFTER SALES SUPPORT

AUS Hotline Costs: Landline calls are free. Mobile costs are extra & are dependenton carrier charges – please check charges with your mobile carrier. MODEL: 21-280467 PRODUCT CODE: 705989 09/2021

1300 883 104AUSsales@4x4tough.com.au, www.4x4tough.com.au YEAR WARRANTY

1

Repair and Refurbished Goods or Parts NoticeUnfortunately, from time to time, faulty products are manufactured which need to be returned to the Supplier for repair.Please be aware that if your product is capable of retaining user-generated data (such as �les stored on a computer hard drive, telephone numbers stored on a mobile telephone, songs stored on a portable media player, games saved on a games console or �les stored on a USB memory stick) during the process of repair, some or all of your stored data may be lost.We recommend you save this data elsewhere prior to sending the product for repair.

You should also be aware that rather than repairing goods, we may replace them with refurbished goods of the same type or use refurbished parts in the repair process.Please be assured though, refurbished parts or replacements are only used where they meet ALDI’s stringent quality specifications.

If at any time you feel your repair is being handled unsatisfactorily, you may escalate your complaint. Please telephone us on 1300 883104 or write to us at:MOTOZONE AUTO ACCESSORIESPO BOX 5213 MORDIALLOC VICTORIA 3197Telephone: 1300 883 104Email: sales@4x4tough.com.au

Remote Control Battery Replacement NoticeOccasionally, during shipment the battery inside the remote control may experience some power loss. For this reason, a replacement battery has been provided inside the re-sealable plastic bag. If, upon initial use of the remote control power loss is experienced, please replace the battery with the spare battery provided. Refer to Page 9. of the User Guide for detailed battery replacement instructions.

The product is guaranteed to be free from defects in workmanship and parts for a period of 12 months from the date of purchase. Defects that occur within this warranty period, under normal use and care, will be repaired, replaced or refunded at our discretion. The bene�ts conferred by this warranty are in addition to all rights and remedies in respect of the product that the consumer has under the Competition and Consumer Act 2010 and similar State and Territory laws.Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Warranty Details12V DC 4WD Electric Winch

Satis�ed customers have repeatedly attested to the positive outcome of asimple phone call in resolving misunderstandings and gaining positive insight

into product usages.

This product is manufactured to the highest standards of safety and performance and is backed by a 1 year warranty.

Please read instructions carefully before use.

Unless directions are followed physical injury or property

damage may result.

Save these instructions for future reference.

In the event you require assistance with your purchase please contact one of our experienced customer service team on

1300 883 104, who will be happy to assist with your enquiry.

Congratulations on choosing to buy a 4X4 TOUGH® product.

WELCOME

4

Please read all instructions carefully before use. Unless directions are followed physical injury or property damage may result. Save these instructions for future reference.

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

1. Dress Properly:• Don't wear loose clothing or jewellery.They can get caught in moving parts.• Wear leather gloves when handling winch rope. Do not handle the rope with bare hands as it can cause injuries.• Non-skid footwear is recommended.• Protective hair covering to contain long hair..

Abuse the Winch Rope:• Never carry the winch by the rope or yank it to disconnect it from the receptacle.• Keep cable away from heat, oil and sharp edges.

3. Don't

4. Don't Overwork the Winch:• If the motor becomes hot to touch, stop and let it cool for a minimum of 15 minutes. • Don't maintain power to the winch if the motor stalls..• Don't exceed maximum line pull ratings shown in the table. (Refer to ‘Line Pull and Cable Capacity Table’ - Page 13)

hock loads must not exceed these ratings.

5. Avoid Unintentional Starting::• To avoid accidental engagement of the winch, ensure your battery isolation switch has been activated after use;

Refer to Installation section on Page 10 this manual.

6. Check Damaged Parts::• Before using, check your winch carefully. Any part that is damaged should be properly repaired or

replaced by an authorised service centre.

7. Repairs to the Winch• This product should only be repaired by a suitably qualified technician using genuine parts.

8. Respool the Cable:• Leather gloves must be worn while respooling. To respool correctly, it is necessary to keep a slight load on the rope.

Hold the rope 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 rope as the winch is powered in.

• Do not allow the rope to slip through your hand and do not approach the winch too closely.• Cautiously spool in the rope under power, keeping hands clear of the fairlead roller to ensure the user is not

exposed to the possibility of having their hand caught.

Warning: The use of any other accessory or attachment other than those recommended in theInstruction manual may present a risk of personal injury and equipment damage.

5

This product has been tests and meets the applicable requirements as set out by standards AS 1418.2-1997 Cranes (including hoists and winches) Serial hoists and winches.

The RCM Mark (Regulatory Compliance Mark) indicates that the product complies with the relevant guidelines of the ACMA as well as government requirements for the safety of electrical devices.

Safety Precautions

Compliance

2. Keep a Safe Distance::• Ensure that all persons stand well clear of winch rope and load during winch operation . 1.5 times the length is

recommended.If the rope pulls loose or breaks under load it can lash back and cause serious personal injury or death.

• Don't step over the rope.• Draping a dampener or similar object over the extended winch rope is recommended as it will dampen any

• All onlookers should be kept away from the work area.• Keep proper footing and balance at all times..

rope

rope back lash.

5

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

1 This winch is fitted with an in-built thermal overload to prevent damage. If the winch stops during operation turn the winch off and allow it to cool before continuing .

2. The uneven spooling of rope, while pulling a load, is not a problem, unless there is a rope pile up on one section of the drum which can damage the winch. If this happens, reverse the winch to relieve the load and move your anchor point further

to the centre of the vehicle. On completion of winching, unspool and rewind for a neat lay of rope on the drum; refer point 14 below.

3. Store the remote control switch inside your vehicle where it wi ll not become damaged. Inspect it before you plug it in.

4. When ready to begin spooling in, plug in remote control switch with clutch disengaged. Do NOT engage clutch with motor running.

5. Never connect the hook back to the rope.This causes rope damage. Always use a sling or chain of suitable strength .

6. Observe your winch while standing at a safe distance. Stop the winching process every metre or so to assure the rope is not pulling up in one corner. Jamming the rope can break your winch.

7. Do not attach tow hooks to winch mounting apparatus.They must be attached to vehicle frame .

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

the winching speed, and the means to maintain a direct line pull to the centre of the fairlead.When double loading during stationary winching, the winch hook should be attached to a rated recovery point on the vehicle.

9. Ensure rated "D" or bow shackles are used in conjunction with an approved tree trunk protector to provide a safe anchor point. Always use shackles that comply with AS/2741 – 2002. A 4.7 Tonne shackle is recommended..

10 When extending winch rope, ensure that at least six wraps of rope remain on drum at all times. Failure to do this could result in the rope parting from the drum under load. Serious personal injury or property damage may result .

111 All winches are provided with a Red Marking on the rope to identify that 6 rope wraps remain on the winch drum. When this mark appears at the rollers, no recovery should be attempted beyond this marking..

12 Since the greatest pulling power is achieved on the inner most layer of your winch, it is desirable to pull off as muchline as you can for heavy pulls (you must leave at least 6 wraps minimum on the drum. If this is not practicaluse a snatch block and double line arrangement .

13 Draping a dampener or similar object over the extended winch rope is recommended as it will dampen any back lash should a failure occur .

14 Neat, tight spooling avoids rope binding, which is caused when a load is applied and the rope is pinched between others. If this happens, alternatively power the winch in and out. Do not attempt to work a bound rope under load - free by hand.

15 Apply blocks to wheels of winching vehicle when vehicles are on an incline..

16 Battery: • Be sure that the vehicle’s battery is in good condition. Avoid contact with battery acid or other contaminants. • Always wear eye protection when working around a battery. • Have the engine running when using the winch to avoid flattening the battery.

Winch Operation Warnings

17 Be sure that the rope is in good condition and is attached properly.

18 Do not use the winch if rope is frayed.

19 Do not move the vehicle to pull a load.

20 Do not replace the rope with a rope of lesser strength.

6

21 The life of the rope is directly related to the use and care it receives. Following its first and subsequent uses, arope must be wound on to the drum under a load of at least approx. 230kg or the outer wraps willdraw into the inner wraps and severely damage the rope during winching.The first winch use should be afamiliarisation run while in a relaxed, non-recovery situation. Spool out the rope until the red cable mark appears(about 6 wraps on the drum), then rewind the rope on to the drum under a load of approx. 230kg or more.This will slightly tension and stretch the new rope and create a tight rope wrap around the drum. Failure to do so may result in rope damage and reduced rope life.

23 Do NOT operate and spool under full load for over one minute continuously.

After use, the winch will be hot. Do not submerge under water or drive through rivers or streams until the unit has cooled down.The IP67 level of waterproofing does not cover the winch when it is hot. IP67 relates to the level of waterproofing of the unit. IP67 covers the unit being submerged in water up to one metre for not more than 30 minutes.

24

22 When the rope is replaced, be sure to apply Loctite, or an equal compound, to the rope clampthread. Tighten the clamp screw properly but do not overtighten. The Loctite will prevent loosening of the screw inarduous conditions. Loctite 7471 Primer and 222 Threadlocker are recommended.

Symbol Index

NOTE:The safety precautions and instructions discussed in this manual can't cover all possibleconditions and situations that may occur. lt must be understood by the operator that commonsense and caution are factors which cannot be built into this product, but must be applied bythe operator.

WINCH SYNTHETIC ROPE

Before Installing Your Winch

MIN . 6

WARNINGThe following symbols appear on your winch and are IMPORTANT WARNINGS  that must be adhered to.

Unpack: Ensure all the listed contents are included. Read and understand the user guide prior to installing the winch on your vehicle.

SYMBOL EXPLANATION

Read all instructions thoroughly prior to installation and useof the winch.

The winch rope has a Red Marking to identify that 6 rope wrapsremain on the winch drum.When this mark appears at the rollers, no recovery should be attemptedbeyond this marking.

NEVER use the winch as a hoist!

7

Use caution when guiding the winch rope in to avoidhands and loose clothing becoming caught.

ITEM QTY DESCRIPTION

1 1 END HOUSING, ASSEMBLY 2 1 DECAL 3 10 SOCKET HEAD CAPSCREW 4 1 DETENT SCREW 5 1 O-RING SEAL 6 1 CLUTCH LEVER 7 2 GASKET 8 1 HEX SHAFT 9 1 SUN GEAR 10 1 CARRIER ASSEMBLY, STAGE 1 11 1 CARRIER ASSEMBLY, STAGE 2 12 1 THRUST BEARING 13 1 CARRIER ASSEMBLY, STAGE 3 14 1 RING GEAR 15 4 FLANGE HEAD CAPSCREW 16 1 DRUM SUPPORT, GEAR TRAIN 16A 1 DRUM SUPPORT, MOTOR 17 2 DRUM BUSHING 18 2 TIE ROD 19 1 DRIVE SPLINED W/RETAINING RING 20 1 DRUM ASSEMBLY 21 1 BUTTON HEAD CAPSCREW 22 1 BRAKE ASSEMBLY 23 1 TERMINAL KIT 24 1 ASSEMBLY 25 1 CLEVIS HOOK 26 1 MOTOR 27 3 BOOT, ELECTRIC TERMINAL 28 1 ROPE ASSEMBLY, ELECTRIC 29 1 HEX HEAD CAPSCREW 30 1 WINCH CONTROL 31 1 TO MOTOR FIELD (BLUE) 32 1 TO MOTOR FIELD (RED) 33 1 TO MOTOR FIELD (YELLOW) 34 1 TO POSITIVE (+) TERMINAL OF BATTERY 35 1 TO EARTH MOTOR 36 1 TO EARTH MOTOR 37 1 TO NEGATIVE (-) TERMINAL OF BATTERY 38 1 REMOTE CONTROL ASSEMBLY 39 1 FAIRLEAD ROLLER

4X4 Tough®12V DC 4WD Winch Parts List

8

4X4 Tough® 12V DC 4WD Winch Parts List

12

3

54

6

7

89

1011

1213

14

1516

A

18 17

27

26

28

29

22

2324

25

2019

17

7

16

38

3036

37

39

34

3332

31

35

21

9

Con

trol c

able

Rem

ote

hand

con

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4X4

Toug

h® 12

V DC

4W

D W

inch

Wiri

ng c

onne

ctio

n po

int f

or w

ired

hand

con

trol l

ead

Gea

r box

Con

trol b

ox

Clu

tch

leve

r

Hea

vy d

uty

3.5

gaug

e le

ads

Cle

vis

hook

Mot

or

Batte

ryis

olat

ion

switc

h

Fairl

ead

rolle

r

Fairl

ead

rolle

r

10

LUBRICATION INFORMATIONAll moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly.Under normal conditions factory lubrication will suffice. If the rope cable becomes worn or damaged it must be replaced.

ROPE INSTALLATIONIt is recommended that if the synthetic rope needs to be replaced you engage a qualified technician to perform this task.AUXILIARY ITEMS (not included)As a further safeguard, you may wish to consider installing the following items:• An additional isolation switch on the positive lead from your battery to avoid the possibility of malicious use by an ill intentioned person.• A second battery to avoid depleting the power of the battery that starts your vehicle, as the use of any winch draws a considerable amount of power.

1. a) The winch is to be mounted into a suitable steel mounting frame using the 4 point foot mounting system in either a horizontal or vertical plane. b) It's very important that the winch be mounted on a flat surface so that the three sections (motor, cable drum and gear housing) are properly aligned. c) Before commencing installation ensure the mounting facility being used is capable of withstanding the winch’s rated capacity. d) The fitment of winches and / or a frontal protection system may affect the triggering of SRS air bags. Check that the mounting system has been tested and approved for winch fitment in the airbag equipped vehicle.

2. Should you wish to manufacture your own mounting plate, the dimensions below will assist. A steel mount plate 6mm thick is recommended. Fasteners should be steel high tensile grade 5 or better. A poorly designed mount may void warranty.

3. The winch should be secured to the mounting with 3/8"UNCx1-1/4" bolts and spring washers provided.

4. The roller fairlead is to be mounted so as to guide the rope onto the drum evenly.

Installation

MOUNTING YOUR WINCH

21-280467 12V DC 4WD Winch - Dimensions (Dimensions are in millimetres)

Front view Top view

165

64

218

TO-C

LEA

R

548 170 254224

114

124

160

device correctly will void any warranty. The manufacturer will not be held responsible for damage caused to property or persons as a result of inadequate installation.

ELECTRICAL CONNECTIONFor 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 battery charged..

Pay close attention to proper electrical cable connection as follows (refer to diagrams below):

1. Short red cable (A) with red jacket connecting to the red terminal (A) of the motor.

2. Short black cable with yellow jacket (B) connecting to the yellow terminal (B) of the motor.

3. Short black cable with blue jacket (C) connecting to the blue terminal (C) of the motor.

4. Thin black cable (Earth) connecting to bottom Earth Terminal of the motor.

5. Long black cable (1.8m) one terminal connecting to the bottom Earth Terminal of the motor, and the other terminal connecting to negative (-) terminal of the battery.

6. Long red cable positive

7. It is essential that the cables are correctly connected by an experienced person who understands the wiring connection procedure. Incorrect wiring may cause the solenoid unit to cease operating.In such cases new solenoid replacements are available for purchase.

(+) connecting to positive (+) terminal of the battery.

11

CAUTION:

CAUTION:

1. Your battery must be kept in good condition.

2. Be sure battery cables are not drawn taught across any surfaces which could possibly damage them.

3. Corrosion on electrical connections will reduce performance or may cause a short.

4. Clean all connections especially in remote control switch and receptacle.

6. Check electrical cables and connections after each use.

5. In salty environments use a silicone sealer to protect from corrosion.

T

Motor - Cable connectionserminal C (Blue)

Terminal A (Red)

Earth Terminal

Terminal B (Yellow)

Control Box - Cable connections

To motor

(Blue)

To motor Terminal A (Red) To motor Terminal B

To motorTerminal C

Earth TerminalTo motor

Earth Terminal

(Yellow)To positive(+)

terminal ofbattery

To negative(-)terminal of

battery

6. To commence winching operation, start vehicle engine, select neutral in transmission and maintain engine speed at idle.

7. Operate the remote control switch to IN or OUT until the vehicle has been retrieved.Stop the winch regularly to ensure that the rope is winding onto the drum evenly.

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 thesound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Soon you will gain confidence in operating your winch and its use will become second nature to you.

Winch Operation

OPERATING:1. Ensure the vehicle is secure by applying the parking brake or chocking the wheels.

2. Pprotector wrapped around a suitably sized tree which will not be damaged by the winching operation.

ull out the winch rope to the desired length and connect to an anchor point. A suggestion would be a tree trunk

The winch clutch allows rapid uncoiling of the rope for hooking onto the load or 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 to the DISENGAGE position. Rope may now be free spooled off the drum.. b) To engage the clutch, move the clutch shifter tab into the ENGAGE position. The winch is now ready for pulling. . 3. Re-check all rope rigging before proceeding.

4. Plug in the winch remote hand control (see Page 10 for instructions). It is recommended that the winching operation

takes place from the driver's position to ensure safe operation.If using the wireless remote control always ensure that you are located at a distance which is greater than 1.5 times the length of the exposed cable.

5. Turn the winch on by turning the on / off orange switch to the on position (clockwise)

OFF ON

OFF

ON

• • •

• • •

•

Never winchCheck the winch carefully and thoroughly before operating.

with your vehicle in gear or in park. This would damage your vehicle's transmission. Never wrap the rope around the object and hook onto the rope itself. This can cause damage to the object beingpulled, and kink or fray the rope.Keep hands, clothing, hair and jewellery clear of the drum area and rope when winching .Never use the winch if the rope is frayed, kinked or damaged .Never allow anyone to stand near the rope, or in line with the rope while it is under load. If the rope should slip or brake, it can suddenly whip back along the line of pull, causing a hazard for anyone in the area.Always stand well to the side while winding.

• ALWAYS disengage the winch when not in use.

12

Note: This guide is recommended for average vehicle rolling loads. Some applications may require a larger winch than indicated.

5443 kg /12,000 lb Line Pull and Cable Capacity Table

Layer of cable 1 2 3 4 5Rated line pull per layer

lb

kgCable capacity ft

m

12000

5443

164.9

9550

4332

3611

8000

3629

6118.6

6800

3084

9027.4

6000

2722

10030.5

Winching Principles

You need a winch to be powerful enough to pull your vehicle while overcoming the added resistance caused by obstacles, moving water, mud, snow, sand or inclines.As a general guide you need a winch with a maximum line pull at least 1.5 times greater than the gross vehicle weight. There are three

and are for reference only.1. Gross Vehicle Weight (Wt): Contains a vehicle weight and the weight of the supplies and equipments carried.2. Surface Drag (S): The characteristics of the terrain or surface to be traversed.

SURFACE TYPE Metal Sand Gravel Soft Sand Mud MarshSurface Drag (s) 0.15 0.18 0.20 0.22 0.32 0.52

3. Gradient resistance: The incline of grade or slope on which the vehicle is being moved.

A gradient of 10% is a rise of one metre in ten metres.

Gradient 5% 10% 20% 30% 50% 70% 100%Angle (ref.) 30 60 110 170 260 350 450Value of (G) 0.06 0.11 0.2 0.3 0.44 0.58 0.71

Rolling Pull Effect required=(Wt X S) + (Wt X G) For example, if a vehicle weighing 2994 kg is winched by 100% on an off road surface, the above formula would be used as follows:

Wt: 2994 kg (gross vehicle weight)

G: 0.71 (gradient value of 100%)

(Wt X S)+ (Wt X G)= 1557 kg + 2126 kg= 3683 kg of effect required to recover the vehicle

Rated Line Pull 12000 lb (5443 kg) single line. Battery Leads 1.80 mWorking voltage Motor Series wound DC 12V with 6hp/4.5 kW Fairlead 4-way roller fairleadGear Train output 3 stage planetary Synthetic Rope 9.5 mm x 26 mGear Ratio 265:1 Drum Size 64 mm x 224 mmClutch Sliding ring gear Dimensions 548 mm x 160 mm x 218 mmBraking Action Automatic in the drum NW. 32kg (70.54lbs)Battery Recommended 650 CCA minimum for winching Mounting Bolt Pattern 254 mm x1 14.3 mm

Line pull lb 0 3000 6000 9000 12000kg 0 1361 2722 4082 5443

Line speed FPM 21.33 11.48 8.20 6.23 4.92MPM 6.5 3.5 2.5 1.9 1.5

Motor current Amps 70 140 200 255 335

13

Remote Hand Control OperationNote: It is recommended that for the initial set-up of the winch (prior to applying any load)

that the winch be operated in the WIRED mode.• Before commencing any operation with the winch using the remote hand control

ensure that the isolator switch on the side of the control box is in the OFF position.• Plug the control cable (with the remote hand controller attached) into the socket on

the control box and turn slightly anti-clockwise to lock into position.• Turn the isolator switch to the ON position.• Once the winch has been set-up then the remote hand control can be operated either

in the WIRED OR WIRELESS mode.• To use the remote hand controller in the WIRELESS mode unplug the remote hand

controller from the control cable.• If at any stage during operation the remote hand controller fails to operate the winch,

reset the control box by turning the isolator switch off then back on.• The hand control is not waterproof and care must be taken in its usage.

In the event of damage or breakage, replacement hand controls are available to be purchased through the 4x4 Tough customer service helpline.

LED light

WIRELESSON/OFF switch

WIRELESSLED indicator

WIREDLED indicator

power ON/OFF

LED light

Cable engage/disengage

Receiver Component Replacement

• To open control box unscrew 4 screws and carefully lift the lid.

Figure 7. Figure 8. Figure 9.

Receivercomponent

• Gently lift out old Receiver Component (do not pull out by the wiring) and unplug. Insert replacement Receiver component.

Control box

Battery Replacement

CAUTION: • Keep battery out of reach of children. • If a child swallows a battery seek medical advise immediately.• Do not use any metallic devices to install battery - this may cause a short circuit.

Battery

Figure 1. Figure 2. Figure 3.

Remote handcontrol

• To open remote hand control unscrew 4 screws and carefully pull apart the two halves.

• To access the battery, pull o� the IN/OUT toggle switch assembly which is inserted into the 6 recesses on the circuit board. Bend the front of the printed panel forward. Once the battery is replaced(en suring the polarity orientation is correct.ie: Match + to +), put back the IN/OUT toggle switch assembly and reassemble the hand control.

PLEASE CONTACT THE AFTER SALES SUPPORT TEAM IF REPLACEMENT PARTS ARE REQUIRED.

The hand control is supplied with a Alkaline 23A 12V battery within the hand control and a spare battery if it requires changing.

14

CAUTION: 1. Your battery must be kept in good condition.2. Be sure battery cables are not drawn taught across any surfaces which could possibly damage them.3. Corrosion on electrical connections will reduce performance or may cause a short.4. Clean all connections especially in remote control switch and receptacle.5. In salty environments use a silicone sealer to protect from corrosion.

It is also recommended to have your winch serviced every 12 months to keep the unit in optimum working condition.Your 4X4 Tough winch should only be serviced by quali�ed persons. Examples include, quali�ed mechanics, auto electricians and engineers. The winch should be removed from the vehicle prior to beginning the service. Please ensure geniune parts are used for any spare parts that may be required during the service. Contact the customer service department on 1300 883 104 if necessary to obtain parts under warranty.Photographs of faulty parts are recommended to support warranty claims. Please email these to sales@4x4tough.com.au

FAQQ: How much rated line pull do I need?

A: Rated line pull refers to the maximum amount of weight that a winch can shoulder, so you need a winch with enoughstrength to handle your vehicle's weight. Thankfully, there is a simple formula for calculating the correct rated line pull: Gross Vehicle Weight x 1.5 = Minimum Rated Line Pull.

Q: Can I remove my winch?

A: Yes. During the o� season, you can unbolt your winch and leave it at home. Some mounts make it easy toremove the winch, and some require a bit more e�ort. Hitch mounts and grille guard mounts are the easiest sincethe winch is so accessible. In a hidden, semi-hidden or replacement bumper setup, the winch sits behind or below the bumper, so removal can be tricky.

Q: Can I operate my winch wirel essly?

A: Yes. While all winches come with a wired remote control, your 4X4 Tough Winch also operates wirelessly. Withmaximum ranges of between 25 and 30 metres, Refer to the operating instructions on page 13 within this manual.

Q: What's the difference between electric and hydraulic winches?

A: The basic di�erence between an electric and a hydraulic winch is the power source. Electric winches link to thevehicles battery, whereas hydraulic winches are driven from the power steering pump. Electric winches are the most prevalent in the market place and as such greater choice is available. They have the advantage of being able to operate without the vehicle running, however as they draw signi�cant power from the battery it is recommended the vehicle be running whilst winching operations are underway .Electric winches generate signi�cant heat and it is important they be run for only short periods of time before being rested to cool down. Hydraulic winches are able tooperate on a more continuous basis, however they can only operate if the vehicle is running.

Disposal • Please consider when disposing of electronic products such as a winch that some components can be recycled and

recovered for re-use. Do not attempt to dissemble any electronic product unless you are a trained electronics technician.

• Many councils hold e-waste (electronic waste) collections. Contact your nearest council to enquire about the best method of disposal in your area.

Maintenance & Storage

It is highly recommended that the winch be used regularly (once a month). Simply power the rope out 15m, free spool 5 m and then power back in. This will keep all components in good working condition.

All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly. Under normal conditions factory lubrication will su�ce. Inspect for any frays in the rope and replace if necessary. If the rope becomes worn or damaged it must be replaced.If you choose to remove the winch from your vehicle, store in an ambient, dry environment until you are ready to re-install

15

16

TROUBLESHOOTING

Problem Possible Cause Suggested corrective action

Motor has di�culty pulling load

Motor runs but winch fails to pull cable

Rope stuck on winch reel

Hook Spreads open

Winch does not operate in wireless mode

Overloaded

Weak battery or connections

Clutch lever is in free spool position

Rope Wedged into lower layers

Point loading

Flat battery in remote hand control

Exceed the wireless distance range

If motor slows down a lot and groans to pull load, the winch is possibly overloaded. Use a pully block to reduce the load on the winch.

Con�rm good clean connections for both positive (+) and ground (-) wires. If connections good, consider battery replacement.

Move clutch lever to the engaged gears position.

Rope may have become wedged between the wraps of lower layers. There is no easy solution to this except to pull on the rope hard enough to pull it free. Avoid this problem by keeping rope neatly and tightly wound on the drum.

Make sure the load is fully engaged into the throat of the hook allowing the safety latch to close. Engaging only the point of the hook on the load could cause hook to open up or break.

The winch is supplied with a Alkaline 23A 12V battery within the hand control and a spare battery if it requires changing. Change the battery in the hand control. Refer to page 15 - Battery replacement.

The 4x4 TOUGH winch operates wirelessly within a range of between 25 and 30 metres. If this distance is exceeded the winch will not operate.