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2.  Motor: Your  motor is powered by a volt battery and provides power to the gear 

mechanism which turns the drum and winds the wire rope; 

3.  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. 

4.  Wire  Rope  (cable)

:

  Your  winch  has  a    galvanized  aircraft  cable  designed 

specifically  for  load  capacity  of  rated  line  pull.  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. 

5.  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. 

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

into extreme pulling forces. 

7.  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.  A 

separate mechanical brake applies the braking action. 

8.  Control System: Your winch was made to provide you the ability  to use it in a 

medley  of  operations.  The  winch  can  be  controlled  by  using  the  Power 

Cord/Switch Assembly or through a solenoid control box.   

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

(“CLUTCH OUT”) the spooling drum from the gear train, free spool. Engaging 

the clutch (“CLUTCH IN”) locks the winch into the gear system. 

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

switch before being directed to the winch motor. 

11. Remote Switch: The Power switch leads have a dual switch for powering in or 

powering out your winch drum. The remote switch allows you to stand clear of 

the wire rope when the winch is under load. 

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

13. Universal  Flat  Bed  Mounting  Channel:  Your winch  could  have  been  optionally 

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. 

Summary of Contents for EWP2500

Page 1: ...ELECTRIC WINCH EWP2500 EWP3500 EWP4500 Assembly Operating Instructions...

Page 2: ...NG 8 WINCH ACCESSORIES YOU WILL NEED 8 RIGGING TECHNIQUES 9 WINCH WORKING DEMONSTRATION 1 0 REPLACING THE WIRE ROPE 1 0 MAINTENANCE 1 1 TROUBLE SHOOTING 1 1 WINCH ASSEMBLY DRAWING EWP2500 EWP3500 1 2...

Page 3: ...itten for your safety Ultimately safe operation of this device rests with you the operator This indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury...

Page 4: ...is a load on the wire rope A separate mechanical brake applies the braking action 8 Control System Your winch was made to provide you the ability to use it in a medley of operations The winch can be c...

Page 5: ...fe distance to the side of the cable when it is 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 reduc...

Page 6: ...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...

Page 7: ...cifications Inspect the winch installation and bolts to ensure that all bolts are tight before each operation Never connect the cable back to itself This will cause cable damage Always use a snatch bl...

Page 8: ...ake sure all spectators are 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 Th...

Page 9: ...el using 2 each of the cap screw assembly Make sure the screw is placed through the mounting channel and roller fairlead from inside the channel This will allow enough clearance for the winch to be pl...

Page 10: ...your connections are accurate If the drum is turning and collecting more cable then reverse the leads on the motor Repeat and check rotation MOUNTING DRAWING The mounting drawing D type A type Switch...

Page 11: ...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 lo...

Page 12: ...the motor stops before reversing directions 7 When the pulling is complete remove the switch assembly From the female connector of the directional valve and replace the female connectors cover Note F...

Page 13: ...onnected improperly Loose battery cable connections Defective switch assembly Defective motor Water has entered motor Re Insert switch assembly into the connector Tighten nuts on all cable connections...

Page 14: ...12 WINCH ASSEMBLY DRAWING EWP2500 EWP3500 2 17 16 15 13 14 12 10 6 8 9 4 3 5 7 2 1 11 29 18 19 20 21 22 23 24 25 26 34 33 35 30 31 32 36 32 31 30 O U T IN IN O U T 40 41 42 37 38 39 8 7 8 43 44 45...

Page 15: ...ch axes 21 P0250019 1 Cam Clutch Gear 22 P0250020 1 Spring 23 P0250021 1 Cover Clutch Housing 24 P0250022 1 Nylon Bearing 25 P0250023 1 Elastic Collar 26 P0250024 1 Clutch Handle 27 P0250025 1 Locking...

Page 16: ...14 WINCH ASSEMBLY DRAWING EWP4500 O U T IN IN O U T...

Page 17: ...300 1 Gear Carrier Assembly Output 20 P0450400 1 Gear Carrier Assembly Intermediate 21 P0450500 1 Gear Carrier Assembly Input 22 P0450017 1 Gear Input Sun 23 P0450018 1 Gasket 24 P0450600 1 Clutch Han...

Page 18: ...4 5 4 4 323mm 113mm 112mm 12 7 4 5 4 4 323mm 113mm 112mm 13 2 4 5 6 5 335mm 113mm 165mm Net weight Ibs kg 19 8 9 0 20 5 9 3 20 5 9 3 Pull Speed Amperes Volts First layer Line Pull Line Speed ft min m...

Page 19: ...35mm 116mm 112mm 13 2 4 6 4 4 335mm 116mm 112mm 13 7 4 6 6 5 348mm 116mm 165mm Net weight Ibs kg 21 3 9 6 22 0 10 0 22 0 10 0 Pull Speed Amperes Volts First layer Line Pull Line Speed ft min m min Cur...

Page 20: ...5mm 123mm 16 1 4 92 4 85 408mm 125mm 123mm 16 1 4 92 6 6 408mm 125mm 168mm Net weight Ibs kg 33 3 15 1 34 2 15 5 34 2 15 5 Pull Speed Amperes Volts First layer Line Pull Line Speed ft min m min Curren...

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