background image

23

Smittybilt Automotive Products, LLC (SAP) warrants to the original purchaser that (a) 

the mechanical components (e.g., gears, clutch, spools, etc.) of any SAP winch will 

be free of defects in material and workmanship for the lifetime of the winch, and (b) 

the electrical components (e.g., electric motor, wires, solenoid, etc.) will be free of 

defects in material and workmanship for a period of five (5) years from the original 

date of purchase. This Warranty applies only to the original purchaser of the winch. 

To obtain any warranty service, you must provide SAP with proof of purchase and 

date of purchase acceptable to SAP, such as a copy of your purchase receipt.
This warranty does not cover the removal or re-installation of the winch. SAP will, 

at its sole option, repair, replace or refund the purchase price of a defective winch 

or component, provided you return the defective winch or component during the 

warranty period, transportation charges prepaid, to SAP. Attach your name, address, 

telephone number, a brief description of the problem, and a copy of your receipt 

and original bill of sale bearing the SAP serial number of the defective winch and 

date of purchase. This warranty does not apply (i) to finish, paint or the wire rope; (ii) 

if the winch has been damaged by accident, abuse, misuse, collision, overloading, 

modification, misapplication, improper installation , or improper service; or (iii) 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 IS THE ONLY WARRANTY. THERE ARE 

NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT 
LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A 
PARTICULAR PURPOSE. ANY IMPLIED WARRANTY WHICH BY LAW MAY NOT 
BE EXCLUDED IS LIMITED IN DURATION TO ONE (1) YEAR FROM THE DATE 
OF ORIGINAL RETAIL PURCHASE OF THE PRODUCT. 

No SAP dealer, agent or 

employee  is  authorized  to  make  any  modification,  extension  or  addition  to  this 

warranty.

 SAP SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL 

OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOST 
PROFITS, DOWN TIME OR LOSS OF USE) UNDER ANY LEGAL THEORY, EVEN 
IF SAP WAS ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. 

Some states 

do  not  allow  the  exclusion  of  implied  warranties  or  the  exclusion  or  limitation  of 

liability  for  incidental  or  consequential  damages,  or  limitations  on  how  long  an 

implied warranty lasts, so the above limitation or exclusion may not apply to you. 

This Warranty gives you specific legal rights. You may also have other rights that 

vary from state to state. SAP reserves the right to change product design without 

notice. In situations in 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  state.  Some  states  do  not  allow  limitations  on  how  long 

an implied warranty lasts, so the above limitations may not apply as to you. Also, 

some states do not allow the exclusion or limitation of incidental or consequential 

damages, so the above limitations or exclusions may not apply to you. Smittybilt 

reserves the right to discontinue product lines and substitute products, or provide 

other  remedies  than  those  listed  in  this  limited  warranty  for  those  discontinued 

products. Instructions, or additional safety information. Smittybilt products, nor the 

warnings contained herein, are not a substitute for your safe driving.
For Technical Support/Warranty Information: 310-762-9944

Smittybilt, 400 W. Artesia Blvd., Compton, California 90220 USA

SMITTYBILT WARRANTY REGISTRATION

Please fill out this form, make a copy and return to Smittybilt, 400 W. Artesia Blvd., Compton, CA 90220. Note: Keep this original for yourself.

First Name:_______________________________________________ Last Name:  _________________________________________________________________

Age:__________ Gender:________ Marital Status:________________ Level of Education:____________________________

City/Province:________________________________ Zip/Postal Code:__________________ Country:________________________

Telephone Number:___________________________ Email Address: ___________________________________________________________________________

Which Smittybilt winch did you purchase? Model Number:______________________________ Date of Purchase: ___________________________________

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 purchased before? _________________________________________________

On what type of vehicle will this winch be installed? Year:____________ Make:_____________ Model:________________ 2WD or 4WD? ________________

What is the vehicle’s main use?  _________________________________________________________________________________________________________

What other accessories have you purchased for your vehicle?  ______________________________________________________________________________

SMITTYBILT ADVANTAGE WARRANTY

LIMITED LIFETIME WARRANTY FOR MECHANICAL COMPONENTS. 

LIMITED FIVE (5) YEAR WARRANTY FOR ELECTRICAL COMPONENTS.

Warranty

Summary of Contents for 97612

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: ......

Reviews: