Smittybilt 97612, Instruction Manual

Page 1: ...1 XRC GEN3 INSTRUCTION MANUAL ...

Page 2: ...Control Box Mounting Bracket Remote Controller with Load Indicator Forged Winch Hook New Remote Controller Features 3 New Control Box Features 4 Safety Precautions 5 Operation Warnings 6 Winch Operation 7 Winch Mounting 8 INSTALLATION INSTRUCTIONS Electrical Connections 10 Auxiliary 12v Power Post 11 Armor Plate Removal 12 Control Box Mounting 14 Wiring for DRL and Tie Bar Lighting 16 Motor Wire N...

Page 3: ...h Power OUT indicator light What do the colored lights on the Load Indicator mean COLOR BLUE READY Winch is ready to start COLOR GREEN LOADING Winch is operating within safe levels COLOR YELLOW MAX LOAD Winch is operating at maximum load COLOR RED OVERLOAD STOP Time to use snatch block or other assist IMPORTANT Load indicator lights will let you know approximately how much load is on your winch ba...

Page 4: ...the cover to expose power post Attach accessory POSITIVE lead to the post Attach accessory NEGATIVE lead to a suitable ground location on your vehicle NOTE you may remove the button head bolt to connect a power wire with an eyelet NEVER operate winch with less than 10 wraps of Synthetic rope around the drum The terminal end is to prevent the rope from unraveling it is NOT a load bearing attachment...

Page 5: ...t oil and sharp edges 4 DO NOT OVERWORK THE WINCH If the motor becomes uncomfortably hot to touch stop and let it cool for a few minutes DO NOT maintain power to the winch if the motor stalls DO NOT exceed maximum line pull ratings shown in tables Shock loads must be avoided Safety Precautions 5 AVOID UNINTENTIONAL OPERATION Winch clutch should be disengaged and the hook secured when not in use an...

Page 6: ...de a safe anchor point 9 When extending winch cable ensure that at least five wraps of cable remain on drum at all times Failure to do this could result in the cable parting from the drum under load Serious personal injury or property damage may result 10 All winches are provided with a red cable marking to identify that 5 cable wraps remain on the winch drum when this mark appears at the rollers ...

Page 7: ...tions due to required hoist safety factors and features 22 Do not use the winch to lift support or otherwise transport personnel WINCH OPERATION 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 recognize the sound of a light st...

Page 8: ...horizontal or vertical plane It is 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 Winch mounting frames and or frontal protection systems are suggested to suit most popular vehicles Winch frames are packaged with detailed fitting instructions The winch should be secured to the mounting with the M10x 32mm ...

Page 9: ...9 INSTALLATION INSTRUCTIONS ...

Page 10: ...and winch wiring connections Doing so can cause property or bodily injury and voids warranty Electrical Connections WARNING Do not alter change or amend winch wiring connections Doing so can cause property or bodily injury and voids warranty ...

Page 11: ... 50 Amp automatic circuit breaker In case of a ground short or thermal overload the breaker will trip it will automatically reset itself after a short period of time after the fault is removed Step 1 Open cover to expose power post Fig 1 Step 2 Attach accessory positive lead to power post Fig 2 Step 3 Attach accessory negative lead to a suitable ground location on your vehicle Note You may remove ...

Page 12: ...o remove it Fig 2 Photos on following page STEP 2 Remove button head bolts holding down the armor plates on to the gear box Fig 3 remove the Allen head bolt holding the gear lever in place Fig 4 Use a 4mm Allen wrench and completely remove screw Not orientation of lever so it can be installed in the same position then pull straight up on the gear lever Gently slide the plate to the right to remove...

Page 13: ...13 Armor Plate Removal ...

Page 14: ...ontrol box mounting brackets to the bottom of the control box with button head bolts Note front to rear orientation Fig 1 2 Step 3 Attach the control box to the tie bars by placing front of bracket over the front tie bar then line up the rear mounting holes with the threaded holes in the rear tie bar Secure with button head bolts Ensure both bolts are started before tightening Note you may loosen ...

Page 15: ... of the winch motor The top will use the countersunk head bolt along with the bracket spacer The bracket spacer will be placed on the winch with the flange towards the top The rear will use the button head bolt and flat washer Ensure both bolts have been started into the threaded holes before tightening Step 3 Loosen the side control box cover bolts just enough to allow them to connect onto the co...

Page 16: ...power source of your choice Note An inline fuse or wiring to a fused circuit is recommended XRC logo light draws approximately 50 mAh XRC Gen 3 winches feature a lighted front tie bar to light up the winch and drum during evening recoveries LED tie bar is illuminated only when you have the remote control plugged in to the control box Step 1 Locate the black wire coming out of the control box and t...

Page 17: ...lement Motor Wire Nuts Mounting Supplement Step 1 Do NOT screw wire nuts too tight Step 2 Put a wrench on bottom nut when installing wire nuts to prevent movement of terminal stud and hold down nut It s helpful to avoid bolt broken during installation See pictures below ...

Page 18: ...ol Included Included Battery Recommended 650 CCA Recommended 650 CCA Battery Leads 25m2 72 L 1 83m 25m2 72 L 1 83m Net Weight 97495 87lbs 39 5kgs 98495 66lbs 30kgs 97612 94lbs 42 5kgs 98612 71lbs 32kgs Overall Dimensions L x W x H 21 7 x 6 7 x 8 3 546x170x210mm 21 7 x 6 7 x 8 3 546x170x210mm Mounting Bolt Pattern 10 x 4 5 254 x 114 3mm 10 x 4 5 254 x 114 3mm Line Pull lbs 0 2000 4000 6000 8000 9 5...

Page 19: ...ration 10 minutes Water equivalent to 3mm rainfall per minute 3 Spraying Water Water falling as a spray at any angle up to 60 from the vertical shall have no harmful effect Test duration 5 min Water volume 0 7 liters per minute Pressure 80 100 kN m2 4 Splashing Water Water splashing against the enclosure from any direction shall have no harmful effect Test duration 5 min Water volume 10 liters per...

Page 20: ...dle seal and hardware XRC Gen3 9 5K 12k 97695 42 Rope fix bolt 9 5K 12K XRC Gen3 9 5K 97695 55 9 5K gearbox asm 9 5k complete gear box XRC Gen3 9 5K 12k 97695 47 Roller Fairlead 9 5K 12K with hardware XRC Gen3 9 5K 12k 97695 77 Hawse Fairlead 9 5K 12K with hardware XRC Gen3 9 5K 12k 97695 53 Control box cover 9 5K 12K XRC Gen3 9 5K 12k 97695 58 Socket covers 9 5K 12K remote and 12v socket covers X...

Page 21: ...e and securing screw XRC Gen312k 97612 57 7 0 hp motor asm12k Winch 12k complete Motor assembly motor side casting seal to drum XRC Gen312k 97612 55 12000 gearbox asm 12k complete Gearbox with gears side casting seal to drum XRC Gen312k 97612 78 Rope 12k Appropriate rope and securing screw XRC Gen312k 97612 41 Cable 12k Appropriate cable and securing screw XRC Gen3 9 5K 12k 97695 49 Complete Contr...

Page 22: ...ature port with switch pressed If voltage is present replace motor Water has entered motor Check for voltage at armature port with switch pressed If voltage is present replace motor Motor runs hot Long period of operation Let winch cool down periodically Motor runs slowly or without normal power Low battery Recharge battery by running vehicle Insufficient current or voltage Clean tighten or replac...

Page 23: ...which SAP has changed a product design SAP shall have no obligation to upgrade or otherwise modify previously manufactured products To assure product quality Smittybilt reserves the right to change product design material specification and finishes without prior notice to customers This limited warranty gives you specific legal rights and you may also have other rights which may vary from state to...

Page 24: ......