Smittybilt 97202 Manual Download | Manualshive

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Step 2 - Install the wiring

• Connect short red cable from remote control to the positive terminal (+) on the
motor.
• Connect short black cable from remote control to the negative terminal (-) on
the motor.
• Connect long red cable from the remote control to the positive terminal (+) of
the battery.
• Connect long black cable from the remote control to the negative terminal (-)
of the battery.

(Wiring Diagram)

To avoid accidental operation DO NOT leave controller hooked/wired up

to winch when not in use.

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Summary of Contents for 97202

Page 1: ...ty Warnings Precautions 03 Installation 08 Mounting the winch 08 Install the wiring 09 Check the system 10 Winch operation 10 Winch Maintenance 11 Troubleshooting 11 Winch Assembly Drawing 12 Winch Parts List 13 Winch Specification 14 Warranty 15 Warranty Information Card 17 ...

Page 2: ... Packing List Description Quantity 1 Winch Assembly with Wire Rope 1 2 Bolt 8MM x 35 6 3 Lock Washers 8 4 Flat Washers 8 5 M8 Nuts 8 6 Bolt 8MMx20 2 7 Clevis Hook with Pin 1 8 Roller Fairlead 1 9 Hook Strap 1 10 Remote 1 11 Winch Plate 1 ...

Page 3: ...azard indicate how to avoid the hazard and advise of the probable consequence of not avoiding the hazard NOTICES are messages to avoid property damage NOTES are additional information to help you complete a procedure PLEASE WORK SAFELY MOVING PARTS ENTANGLEMENTHAZARD Failure to observe these instructions could lead to severe injury or death To avoid injury to hands or fingers Always keep hands cle...

Page 4: ... remote control lead clear of the drum rope and rigging Inspect for cracks pinches frayed wires or loose connections Replace remote control if damaged Always pass wired remote control through a window to avoid pinching lead in door when using remote inside a vehicle Never leave remote control where it can be activated during freespooling rigging or when the winch is not being used Always require o...

Page 5: ...l the rope onto the drum in the direction specified by the winch warning label on the winch and or documentation This is required for the automatic brake if so equipped to function properly Always prestretch wire rope and respool under load before use Tightly wound wire rope reduces chances of binding which can damage the rope MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions ...

Page 6: ...nd clear of rope and load and keep others away while winching Always be aware of stability of vehicle and load during winching keep others away Alert all bystanders of any unstable condition Never use winch to secure a load MOVING PARTS ENTANGLEMENT HAZARD Always use a hook with a latch Always insure hook latch is closed and not supporting load Never apply load to hook tip or latch Apply load only...

Page 7: ...ged or disengaged Never use winch to tow other vehicles or objects Shock loads can momentarily exceed capacity of rope and winch Always avoid powering out for extended distances This causes excess heat and wear on the winch motor and brake Always use care to not damage the vehicle frame when anchoring to a vehicle during a winching operation Never jog rope under load Shock loads can momentarily ex...

Page 8: ...r moving parts Do NOT route electrical cables through or near any high heat parts Avoid pinch and wear abrasion points when installing all electrical cables Installation Step 1 Mount the winch To secure the winch always use A flat secure mounting location at least 4 8 mm 3 16 in thick Lock washers Hex head cap screws when using a one piece winch mount plate Torque the mounting bolts to 16 N m 12 l...

Page 9: ...m remote control to the negative terminal on the motor Connect long red cable from the remote control to the positive terminal of the battery Connect long black cable from the remote control to the negative terminal of the battery Wiring Diagram To avoid accidental operation DO NOT leave controller hooked wired up to winch when not in use ...

Page 10: ...osed wiring or terminals Check winch for proper operation The wire rope should spool in and out in the direction indicated on the switch Step 4 Winch operation To free spool pull knob out and twist approx Fig A When powering in make sure winch is engaged twisting know back and knob is all of the way back in Push IN button on remote Fig B Fig A Fig B ...

Page 11: ...ge the clutch and out of reach for children Check each assembly or connection screw if loosen or corrode please repair and replace before use Troubleshooting NO Symptom Possible Cause Suggested solution 1 Motor does not turn on Switch Assembly not connected property Loose battery cable Connections Defective motor Insert Switch Assembly all the way into the connector Tighten nuts on all cable conne...

Page 12: ...12 Winch Assembly Drawing ...

Page 13: ...2 09 1 Spring 10 97202 10 1 Drum Assembly 11 97202 11 1 Screw 12 97202 12 1 T Series Bushing 13 97202 13 1 Thick Flat Washer 14 97202 14 2 Hex Flange Nut 15 97202 15 1 T Series Base plate Assembly 16 97202 16 1 Tension Plate 17 97202 17 1 T Series F W Knob Assembly 18 97202 18 1 Elastic Pin 19 97202 19 2 Hex Socket Screw 20 97202 20 2 Screw 21 97202 21 2 Screw 22 97202 22 2 Flat Washer 23 97202 23...

Page 14: ... x 4 W x 4 1 H Net weight 12lbs Line speed and motor current first layer Line pull LBS 0 500 1 000 1 500 2 000 KGS 0 227 454 680 907 Line speed FPM 13 10 7 7 7 5 6 3 3 MPM 3 9 3 2 2 3 1 7 1 Motor current Amps 9 30 58 81 110 Line pull and cable capacity Layer of cable 1 2 3 4 5 6 Rated line pull per layer LBS 2 000 1630 1380 1190 1050 940 KGS 907 740 620 540 470 420 Cable capacity per layer Ft 6 5 ...

Page 15: ...i any normally wearable part such as the break mechanism This Warranty is void if any SAP serial number has been removed or defaced Commercial or industrial use or application or any hoisting application of the winch voids the Warranty This Warranty is good only for winches bought sold and used in the United States unless otherwise specifically agreed in writing by SAP THE WARRANTY SET FORTH ABOVE...

Page 16: ... the fullest extent permitted by applicable law the following are hereby excluded and disclaimed 1 All warranties of fitness for a particular purpose 2 All warranties of Merchantability 3 All claims for consequential or incidental damages There are no warranties that extend beyond the description that appears on the face hereof Some states do not allow the above exclusions or disclaimers in consum...

Page 17: ... Where did you purchase this product Store or catalog name Store Location How satisfied were you with the dealer and or sales staff Who installed or will install your Smittybilt product Is this the first time you have purchase a winch If no what brand have you brought before What type of vehicle will this Smittybilt winch be installed on Year Make Model 2WD 4WD What is the vehicles main use What o...

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