ZEAK 2500LB, Manual

Page 1: ...ZEAK 2500LB WINCH ...

Page 2: ...ATION INSTRUCTIONS before operating Failure to follow the safety rules and other basic safety precautions may result in serious personal injury Keep this manual and the receipt in a safe and dry place for future reference ZEAK 2500LB Electric ATV WINCH 12 Volt ...

Page 3: ...Work Area Safety 1 Personal Safety 2 2 General Safety 3 3 3 Installation Safety 5 Winching Safety Mounting the Solenoid Assembly 7 Circuit Break Protection Rubber Sleeve 9 Clutch Operation 10 Operation Warning 11 6 TROUBLESHOOTING 14 7 MAINTENANCE 15 8 PARTS DIAGRAM 16 9 REPLACEMENT PART 17 Duty Cycle 13 Wiring 8 4 ASSEMBLY INSTRUCTIONS Mounting the Winch 7 Hazardous Chemicals Warning 1 ...

Page 4: ...nditions or situations that could occur Exercise common sense and caution when using this electric winch Always be aware of the environment and ensure that the electric winch is used in a safe and responsible manner Do not modify this electric winch in any way Unauthorized modification may impair the function and or safety and could affect the life of the electric winch There are specific applicat...

Page 5: ...he work area Inspect before every use do not use if damaged or parts loose Examine the winch for structural cracks bends damage frayed or kinked wire rope and any other conditions that may affect the safe operate of the winch Do not use the winch even if minor damage appears A kink permanently weakens the wire rope even after it is straightened out kinked wire rope can fail suddenly and must not b...

Page 6: ...ntilate area well before and while working on battery Explosive hydrogen gas can accumulate and explode when ignited by a spark or open flame 8 Only connect to a clean corrosion free battery 9 Remove all jewelry and metallic objects before working near battery Winching Safety 1 Inspect winch rope hook and slings before operating winch Frayed kinked or damaged winch rope must be replaced immediatel...

Page 7: ...n the drum 22 Keep clear of the wire rope hook and load while winching Do not step over the wire rope Do not push sideways against the wire rope under tension wire rope might break under this load and recoil back striking the person pushing against it or a bystander 23 If the wire rope begins to get entangled stop the winch immediately and release the wire rope using the switch 24 Only winch with ...

Page 8: ...tion to any off road adventure Technical Specifications 5 Layer Wire Rope Capacity Rated Line Pull First layer of Wire Rope Performance 2 1 3 4 5 6 2500lb 1134kg 6 1 8m 2045lb 928kg 13 3 4 0m 1731lb 785kg 21 9 6 7m 1500lb 680kg 31 8 9 7m 1324lb 600kg 43 1 13 1m 1184lb 537kg 50 15 2m Line Pull lb Amp Draw 12v Line Speed fpm mpm 1 0 13 3 4 1 10 1000 8 3 2 5 55 2000 4 1 1 2 106 2500 2 7 0 8 132 ...

Page 9: ...DC Battery Cables 10 Gauge 5 8 long Solenoid Cables 10 Gauge 1 3 long Solenoid Solenoid Weather sealed Mounting Bolt Pattern 3 15 80mm 3x G8 Winch M8 1 25X35mm 2x G8 Fairlead M8 1 25 X19mm Warranty one year Mounting Hardware Rope Material Synthetic Rope Length ft 50 Rope Diameter in 3 16 Sound Rating 85dB Dimensions 11 7 x3 97 x4 13 Weight 13 55 lb IP Rating IP 65 Duty Cycle Rating 5 45 Sec at Max...

Page 10: ...o weld on additional brac ing depending on the mounting location 4 Drill holes appropriate for the hardware at the marked locations 5 Install the winch using hardware described under Specifications Mounting the Solenoid Assembly 1 Mount the solenoid box in proper location so that a The winch components are close enough to each other to allow wires to be routed properly b The vehicle component oper...

Page 11: ...omponents which may create damage to the wiring through heat or motion or create a fire hazard 2 If you drill through the bumper or any part of the body to route the wires be sure to install a rubber grommet in the hole to prevent fraying of the wires at that point 3 Route the cables from the solenoid to the battery and from the solenoid to the winch following the precautions discussed above See t...

Page 12: ...ect for 5 full wraps 3 Recoil the rope back into the winch under at least 500lb of tension Circuit Break Protection Rubber Sleeve 9 How to Use It You only need to heat it evenly with a hot air blower or a candle to make it shrink they can be used for circuit break protection group of lines marking resistance electric capacity reason protection ...

Page 13: ...ic objects before working near battery Warning 1 Read the entire Important Safety Information section at the beginning of this winch 2 The instructions that follow are basic guidelines only and cannot cover all situations encountered during use The operator and assistants must carefully plan usage to prevent accidents Clutch Operation 1 The position of the pin in the shaft determines whether the c...

Page 14: ...ncy brake and block the wheels using wheel chocks sold separately 6 Hook onto the object using a pulling point tow strap tree strap or chain See the following picture 8 Do not use a recovery strap while winching They are designed to stretch and can suddenly whip back towards the operator during a winching operation 9 Place a heavy rag or carpet sold separately over the wire rope span 6 feet from t...

Page 15: ... Do not power the hook all the way into the fairlead to prevent damage 14 Do not operate the winch at extreme angles Do not exceed the angles shown below for a roller fairlead For a hawse fairlead the angle should be as close to straight as possible 15 If the object to be pulled must be pulled at an angle in relation to the winch use a pulley sold separately and an anchor point directly in front o...

Page 16: ...the hook from the load and reel in the wire rope 19 Disconnect the pendant controller if equipped after use Duty Cycle Avoid damage to the winch by not winching for more than the prescribed duty cycle time The duty cycle defines the amount of time within a 15 minutes period during which a winch can operate at its maximum capacity without overheating For example this winch with a 5 duty cycle at it...

Page 17: ...le connections 3 Fully charge battery 4 Tap solenoid to loosen contacts Apply 12 volts to coil terminals directly A clicking indicates proper activation 5 Replace remote 6 Check for voltage at armature port with switch pressed If voltage is present replace motor 7 Allow to drain and dry Run in short bursts without load until completely dry 8 Have technician service winch Motor runs but wire rope d...

Page 18: ...ury from winch failure do not use damaged equipment If an abnormal noise or vibration occurs have the problem corrected before further use 4 Lubricate the wire rope occasionally corrected before further use 5 The winch s internal mechanism is a permanently lubricated Do not open the housing However if the winch is submerged it should be opened dried and re lu bricated by a qualified technician as ...

Page 19: ...ushing Pan Head Screw M4X 12MM Drum Support Plate Rotator Gear Gear Ring Planetary Gear Assembly Motor Winch Mounting Hardware Hawse Fairlead Fairlead Mounting Hardware Hook Red Strap Pendant Controller Control Box Circuit Breaker Parts List Part Number Description Quantity Clutch Knob 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 4 1 2 2 2 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 23 24 25...

Page 20: ...lustrations provide are a convenient reference to the location and position of parts in the assembly sequence When ordering parts the following information will be required item descrip tion item model number item serial number item lot date code and the replace ment part number 17 ...