Bushranger DV-12TH, Manual

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Page 2: ... 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 How to make a warranty claim A claim under the Warranty must be made within the Warranty period identified below which commences on the date of purchase from Kingsley To make a Warranty claim the Product must be returned to the place of purchase together with pro...

Page 3: ... and a lifetime for mechanical components from the date of purchase from Kingsley The warranty against defects contained in this document replaces any other warranty against defects or voluntary warranty given in relation to the products Kingsley Enterprises Pty Ltd 6A Brooks Road Ingleburn 2565 New South Wales Australia Phone 1800 654 767 International 612 8700 0400 Email sales kingsleyenterprise...

Page 4: ...give the following information 1 Winch model and voltage 2 Serial Number 3 Item No and Part Number 4 Part Description 1 It is highly recommended that prior to using this off road vehicle recovery device that users undertake off road training including vehicle recovery Recovering immobilised vehicles is a potentially dangerous exercise and this winch is to be used with great care 2 The winch is rat...

Page 5: ...t for vertical lifting and moving people Ensure that the winch is connected to the correct voltage 12VDC only Do not exceed the maximum line pull ratings shown in this manual Shock loads must not exceed these ratings Pull from an angle below 15 in the horizontal plane to straighten up the vehicle or load Always use leather gloves when handling the wire rope When winching always use a recovery damp...

Page 6: ...nsufficient power when winching a load the vehicle should be running and in neutral Keep the remote control clear of the rope at all times If noise or vibration occurs when running stop the winch immediately and inspect or return it for repair The rope must be wound in an under wound orientation only to ensure correct brake operation Always inspect the hook latch and pin prior to use Do not use if...

Page 7: ...oad A full drum delivers the maximum speed and the minimum load Refer to winch specifications Pages 28 30 For this reason automotive winches are rated at their first layer capacities Duty Cycle Ratings Duty cycle ratings usually specify continuous intermittent or special duty typically expressed in minutes The IEC International Electrotechnical Commission lists the following ratings S1 Continuous ...

Page 8: ...le The values and calculations in this section are approximate and are for reference only a Gross vehicle mass GVM b Type of surface to be traversed c Gradient to overcome In recovery and loading where the winch is used to pull something the required pulling force RPF can be calculated according to the formula RPF Wt X S Wt X G Where Wt the gross vehicle mass GVM S the type of surface to be traver...

Page 9: ...on a marshy surface the above formula would be used as follows Where Wt 3 000kg S 0 52 G 0 71 RPF Wt X S Wt X G 3 000kg X 0 52 3 000kg X 0 71 1 560kg 2 130kg 3 690kg of effect required to recover the vehicle Note A gradient of 10 is a rise of one metre in ten metres Height Distance ...

Page 10: ...hey must be located at least 100cm 40 apart Tree Trunk Protector Strap A tree trunk protector strap is useful for connecting a rope to almost any anchor point but is primarily designed to prevent a tree from ring barking The tree trunk protector should be wrapped around the chosen tree or anchor point as low to the ground as possible and the two ends brought together and joined with a bow shackle ...

Page 11: ...ng load limit or SWL safe working load The shackles or any other recovery equipment used should be sized correctly for the winching task Preparation before Winching 1 Connecting the remote control When connecting the remote control always keep the remote control free from the winch rope and fairlead Always disconnect the remote control when not in use 2 Disengaging the clutch Lift the clutch T han...

Page 12: ...hicle the rescue vehicle is considered the anchor point and should be made secure The anchor point must be strong enough to hold the gross weight of the vehicle and be positioned to keep the fleet angle between the centre of the anchor point and the wire rope maintained at less than 15 Always use a tree trunk protector strap to prevent ring barking the tree and damage to the rope Winch Operation 1...

Page 13: ...ehicle engine should be running to provide maximum power to the winch The transmission should be set in neutral hand brake applied and wheels chocked or vehicle anchored to prevent the vehicle from moving 5 Attach shackle and hook Use a shackle to lock both ends of the tree trunk protector and then attach to the rope hook 6 Begin winching Keep tension on the rope to ensure it winds onto the drum t...

Page 14: ...store it in a safe dry and easily accessible place Precautions whilst winching Make sure the rope is wound onto the drum tightly and evenly Allowing the rope to become loosely wound can result in binding pinching and wedging between layers ultimately damaging the rope shortening its life and increasing the risk of injury and failure under load Always keep clear of the winch rope hook and fairlead ...

Page 15: ...amage to the cord may result A winching operation requires extra consumption of battery power so always maintain your battery set in a good condition Thermal Sensor Warning LED The warning LEDs are shown on the remote control for DV 9TH Seal 9 5TH and DV 12TH automotive winch models Green LED illuminates when the winch is operating under normal working conditions Red LED illuminates when the winch...

Page 16: ...rope for hooking onto a load or anchor point and is operated by a clutch T handle The clutch T handle must be returned to the Engaged position before winching 1 To disengage lift the clutch T handle and turn it 90 in a counter clockwise direction to the Disengaged position Rope can now free spool off the drum 2 To engage lift the clutch T handle and turn it 90 in a clockwise direction to the Engag...

Page 17: ...lation is performed by an authorised technician familiar with this product Before using the winch make sure all electrical components have no corrosion or damage Mounting It is very important that the winch is mounted on a flat and hard surface or mounting channel or in a suitable winch compatible bull bar to ensure the motor drum and gearbox housing are aligned correctly The fairlead is not desig...

Page 18: ... pitch 8 8 grade high tensile steel bolts supplied must be used for fastening the fairlead into the mounting channel Torque Settings Maximum M10 x 1 5 8 8 Grade 44 N m M12 x 1 75 8 8 Grade 76 N m Drain Plug Orientation For DV 9TH DV 12TH it is important that the rubber drain plug on the bottom of the 12V motor is orientated to face down to the ground to allow for effective drainage If the winch is...

Page 19: ...ay should be switched at the vehicle ignition when the accessories are turned on The battery isolator Relay must be rated to handle more than the winch s maximum amp draw under load Consult a qualified automotive electrician for supply and installation of a suitable devise Nut Fastening for Motor Contactor The nuts on the motor and contactor should be fastened to the specified torque as outlined i...

Page 20: ...aged since the outer layers of rope can draw down into the inner layers leading to binding pinching or wedging between layers One method for tensioning the rope onto the drum is to use the weight of the vehicle on a slight incline to pull on the rope while spooling in This can be achieved by following the steps outlined in the previous section Winching Procedures Page 10 Prior to spooling in under...

Page 21: ...ts that secure the brake cover then remove the brake cover 2 Loosen and remove the 6 bolts retaining the gearbox housing 3 Rotate the gearbox housing to achieve the target angle as detailed below 4 Reinstall and tighten all bolts and covers removed in previous steps Tighten bolts to 6Nm DV 9TH Gearbox Rotation Increments SEAL 9 5TH Gearbox Rotation Increments SEAL 9 5TH Exploded View DV 9TH Explod...

Page 22: ...using externally visible brake cover does not need to be removed 2 Rotate the gearbox housing to achieve the target angle as detailed below 3 Reinstall and tighten all bolts removed in previous steps Tighten bolts to 6Nm DV 12TH Gearbox Rotation Increments DV 12TH Exploded View ...

Page 23: ...the clevis hook to the thimble end of the rope and ensure the split cotter pin is correctly installed to secure the pin 5 Wind the red section of rope onto the drum tightly and evenly under hand tension to have a minimum of five 5 wraps of wire rope on the drum 6 Follow the procedure outlined in the previous sections Rope Preparation Page 19 and Winching Procedures Page 10 to complete the installa...

Page 24: ...rectly installed to secure the pin 7 Wind the red section of rope onto the drum tightly and evenly under hand tension to have a minimum of ten 10 wraps of wire rope on the drum 8 Follow the procedure outlined in the previous sections Rope Preparation Page 19 and Winching Procedures Page 10 to complete the installation of the replacement wire rope 9 A minimum of ten 10 wraps of synthetic rope aroun...

Page 25: ...ckwise by 150 180 degrees Lubrication Servicing Servicing and repairs should only be carried out by an authorised dealer Unauthorised repairs or servicing will void warranty The winch should be used regularly to ensure components are kept in good working order At a minimum it is recommended that the rope is powered out and then powered back in on a monthly basis by following the correct winching p...

Page 26: ...ould be drained periodically to ensure any moisture or water build up is removed Pull down on the rubber plug to allow for drainage Ensure the rubber plug is re seated in the hole correctly to prevent water and debris from entering during use Cleaning Only use low pressure water to clean the synthetic rope Do not use any chemicals Use low pressure water and a soapy sponge to clean the winch If hig...

Page 27: ... Deforming or corrosion Visual Existence of abnormalities Fastening to hook and drum assemblies Visual Existence of abnormalities Synthetic rope Broken strands Visual measuring Two or more adjacent strands are cut Decrease in rope diameter Visual measuring 25 of nominal diameter max Fused or melted fibres Visual Existence of abnormalities Fastening condition of end Visual Existence of abnormalitie...

Page 28: ... is mechanically binding up Check to insure the winch is mounted on a flat rigid surface Damaged brake cam and disc Replace brake cam and disc Damaged gear box Replace gear box Faulty retaining ring Replace retaining ring Oil leakage at brake cavity Clean oil leakage Damaged or inoperative spiral spring Replace and position spiral spring Braking distance is too long Worn brake disc or loose brake ...

Page 29: ...x 227mm 2 5 x 8 9 Mounting Bolts Pattern 254mm x 114mm 10 x 4 5 Winch weight 33kg 72 8lb Gross weight 43kg 94 8lb Performance Specifications 1st Layer of Drum Pull by Layer Load Line Speed Motor Current Total Rope on kg lb mpm fpm amps Layer kg lb Drum m ft No load 13 4 44 55 1 4 082 9 000 6 1 20 907 2 000 4 6 15 110 2 3 316 7 310 13 6 44 7 1 814 4 000 3 4 11 200 3 2 792 6 154 22 6 74 2 722 6 000 ...

Page 30: ...27mm 2 5 x 8 9 Mounting Bolts Pattern 254mm x 114mm 10 x 4 5 Winch Weight 28kg 61 7lb Gross Weight 40 5kg 89 1lb Performance Specifications 1st Layer of Drum Pull by Layer Load Line Speed Motor Current Total Rope on kg lb mpm fpm amps Layer kg lb Drum m ft No load 19 62 60 1 4 309 9 500 5 8 19 1 907 2 000 4 7 15 2 115 2 3 472 7 655 13 1 42 9 1 814 4 000 3 5 11 5 210 3 2 908 6 410 21 7 71 2 2 722 6...

Page 31: ...mm 3 5 x 8 1 Mounting Bolts Pattern 254mm x 114mm x 165mm 10 x 4 5 x 6 5 Winch Weight 55kg 121lb Gross Weight 67kg 147 7lb Performance Specifications 1st Layer of Drum Pull by Layer Load Line Speed Motor Current Total Rope on kg lb mpm fpm amps Layer kg lb Drum m ft No load 8 3 27 60 1 5 443 12 000 6 6 21 5 1 814 4 000 2 6 8 6 200 2 4 563 10 060 14 4 47 2 3 629 8 000 1 7 5 8 310 3 3 928 8 659 23 5...

Page 32: ...5 1 15 1 st stage carrier 880016 1 16 1 st 2 nd ring gear 880017 1 17 1 st pinion kit 880018 1 18 Clutch kit 881303 1 19 Gear box kit 880020 1 20 Cone brake disc kit 880021 1 21 Brake cover kit 880022 1 22 Roller fairlead 880066 1 23 Mounting hardware 880024 1 24 Remote control 880126 1 25 Hand saver strap 881394 1 26 Detachable control box 12V 881166 1 Detachable control box 24V 881167 26 1 Remot...

Page 33: ...Page 32 Winch Assembly DV 9TH ...

Page 34: ...tage carrier 880116 1 13 1 st stage carrier 880117 1 14 1 st 2 nd ring gear 880118 1 15 1 st pinion 880119 1 16 Clutch kit 881564 1 17 Gear box kit 880121 1 18 Cone brake disc kit 880122 1 19 Brake cover kit 880123 1 20 Hawse fairlead 882167 1 21 Mounting hardware 880024 1 22 Remote control 880126 1 23 Hand saver strap 881394 1 24 Detachable control box 12V 881166 1 24 1 Remote socket kit 12V 8813...

Page 35: ...Page 34 Winch Assembly SEAL 9 5TH ...

Page 36: ...15 Retaining ring 880058 1 16 1 st 2 nd ring gear 880059 1 17 1 st pinion 880060 1 18 Clutch kit 880061 1 19 Gear box kit 880062 1 20 Brake base 880063 1 21 Cone brake disc kit 880021 1 22 Brake cover kit 880065 1 23 Roller fairlead 880066 1 24 Mounting hardware 880067 1 25 Remote control 880126 1 26 Handsaver strap 881394 1 27 Detachable control box 12V 881166 1 Detachable control box 24V 881167 ...

Page 37: ...Page 36 Winch Assembly DV 12TH ...

Page 38: ...Page 37 NOTES ...

Page 39: ...Enterprises Pty Ltd 6A Brooks Rd Ingleburn NSW 2565 Sydney Australia Phone 1800 654 767 Toll Free International Calls 61 2 8700 0400 Fax 02 8700 0499 www bushranger com au INSTRUCTION NO IO23 ISSUED MARCH 2013 REV 1 DA ...

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