Mile Marker PE4500 ES, Installation And Operator'S Manual

Page 1: ...Installation and Operator s Manual Project ES Winch System PE4500 Es Pn 76 50115BW sEC8 Es Pn 77 50141W sEC8 scout Es Pn 77 53141W sEC95 Es Pn 76 50246BW sEC12 Es Pn 76 50251BW sEC15 Es Pn 76 50260W ...

Page 2: ...recautions 3 Winching Tips Techniques 6 Getting Started Unpacking Your Winch 8 Winch Mounting 8 Clocking Instructions 9 Control Box Installation 10 WinchOperation 14 Maintenance 15 Troubleshooting 15 Features 16 Parts Lists 19 Warranty 25 ...

Page 3: ...TIONS Keep the working area well lit Do not use this winch in the presence of flammable gases or liquids 5 KEEP CHILDREN AWAY Keep children away from working area Never let children operate the winch 6 DRESS PROPERLY Do not wear loose clothing or jewelry as they can be caught in moving parts Protective electrically non conductive clothes and non skid footwear is the only typeof clothing you should...

Page 4: ...nd of the drum When possible please get the rope as straight as possible to the direction of the object 14 NEVER OPERATE THE WINCH WITHOUT THE ROPE FAIRLEAD FITTED Operator injury or winch damage can result if a fairlead is not installed 15 STAY ALERT Watch what you are doing Use your common sense Do not use this winch when you are tired stressed or WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MED...

Page 5: ...d or kinked 16 Do not cross over or under the cable while it is in process of loading 17 Do not move vehicle with cable extended and at tached to load to pull it The cable could snap 18 Apply blocks such as a wheel choke to vehicle when parked on an incline 19 Re spool cable properly 1 Keeps hands and body away from Fairlead cable intake slot when operating 2 Secure vehicle in position before usin...

Page 6: ...ve the blanket or jacket as winching proceeds but halt winching when doing so Partially raising the hood of the vehicle will also give a measure of protection to its occupants from broken rope or cable consistent with suf ficient forward visibility for the operator WINCHING TIPS AND USE OF A SNATCH BLOCK Use OEM tow hooks recovery eyes or a clevis mount for attach ment of a tow strap or winch cabl...

Page 7: ...or soft ground Pulleyblockattachedtoloadusingasuitableanchor point Note the angled direction taken by the load and subse quent angle of rope feed back on the winch drum extreme example shown There may be unavoidable circumstances requiring this mode though in general it is not recommend ed unless applied in stages by moving the anchor point or vehicle to avoid the sharp angled rewind on the winch ...

Page 8: ...r where the full rated load will be evenly distributed CAUTION It is essential that the mounting surface be flat and the winch is mounted such that the three major sections Gear housing end drum and motor end are in proper alignment 1 Drill four mounting holes 10mm in Dia if necessary according to the bolt pattern mentioned in the winch specifications 2 Fasten the winch body to the mounting platfo...

Page 9: ... at 8 equidistant locations 0 45 90 360 1 Remove Gear Housing from Tie Bars Fig 1 2 2 Remove the 8 bolts in the Gear Housing Leg Fig 1 3 3 Separate Leg and Gear Housing A slight tap with a hammer might be needed Fig 1 4 4 Place Gear Housing Leg in the angle desired and screw in bolts Fig 1 5 Torque to spec M4 X 12 Item 2 2 ft lb M8 X 25 Item 6 18 ft lb M6 X 12 Item 40 7 5 ft lb M5 X 16 Item 41 4 5...

Page 10: ... wrench a metric Allen wrench set and a pair of snips Also you will need general hand tools for mounting the winch Your Project ES control box can be mounted over the winch motor or over the tie bars This decision is usually based on mounting constraints and personal prefer ence Figure 2 1 shows the control box and mounting hardware includ ed in your new winch box Mounting Control Box on Motor If ...

Page 11: ...Control Box Installation Cont d 11 2 5 Screw bolts with control box in the mounting points Mounting Points Mounting Control Box on Motor Cont d 2 6 Attach Tie Wrap 2 7 Clip Excess Length ...

Page 12: ... the control box with a 10mm wrench Mounting Control Box on Tiebars 1 Mount the control box to mounting brackets using 10 mm wrench Fig 2 8 2 Mount control box on the tie bars by attaching front end first and pushing down to snap in the back end Fig 2 9 3 Locate the two extra pieces for the tie bars mounting brackets Fig 2 10 4 Screw in these pieces to the rear side of the tie bar bracket using a ...

Page 13: ...ding interference with moving parts and abrasion points which could potentially cause electrical short 2 12 Complete Wiring Schematic SEC8 CAUTION Do Not Connect Cables to Battery until unit is completely wired to control box and installed on ve hicle Reserve for last step of installation CAUTION Do Not Connect Cables to Battery until unit is completely wired to control box and installed on ve hic...

Page 14: ...inching operation Usage of a snatch block is recommended to reduce the load on the winch motor All Mile Marker Electric Winches feature an Automatic Load Holding brake so never run the winch against the brake OUT on the hand control for more than 10 seconds Failure to do so might result in damage to the brake and motor Always stay clear of the loaded winch cable Operational Instructions 1 Disengag...

Page 15: ...not turn on Safety switch is OFF Switch Assy not connected properly Loose battery cable Solenoid malfunctioning Defective Switch Assembly Defective motor Water has entered motor Turn safety switch to ON position Insert Switch Assy firmly to the connector Tighten nuts on cable connectors Tap solenoid to free contact applying 12 volts to coil terminal directly Makes an audible clicking when activati...

Page 16: ...hetic Rope 5 16 x 100 13 700 nominal 7 94 MM X 30 5M Drum Size Diameter Length 2 5 6 4 cm 9 23cm Net weight 81 lbs 37 kg Bolt Pattern 10 x 4 5 254MM X 114MM 4 bolts 3 8 Specifications Specifications Performance Performance lbs kgs fpm mpm amps 12v 0 0 26 7 9 95 2000 907 20 6 175 4000 1814 14 4 3 240 6000 2722 12 3 8 295 8000 3629 10 8 3 3 370 lbs kgs fpm mpm amps 12v 0 0 26 7 9 95 2000 907 20 6 17...

Page 17: ...In Power Out Low Electric Current Galvanized Roller Fairlead Series Wound Motor Winch Features and Specs SEC12 Winch Features and Specs SEC95 ES Part Number 76 50246BW Rated line pull single line 9 500 LBS 4309 kg Gear Train 3 Stage Planetary Gear Ratio 212 1 Motor Series Wound 4 8 HP 3 6 KW 12 24 V Control Pendant Power In Power Out Remote 12 3 7 m Dimensions LxWxH 22 5 X 6 25 X 8 0 565 2 mm X 15...

Page 18: ... Out Low Electric Current Galvanized Roller Fairlead Series Wound Motor Winch Features and Specs SEC15 ES Features Winch Features and Specs PE4500 ES Part Number 76 50115BW Rated line pull single line 4 500 LBS 2041 kg Gear Train 3 Stage Planetary Gear Ratio 294 1 Motor 1 9 HPPermanent Magnet 1 4 KW 12V Control Pendant Power In Power Out Remote 12 3 7 m Dimensions LxWxH 17 2 X 6 2 X 7 3 436 MM X 1...

Page 19: ... 03 Spring Washer M4 4 1 77 50141W 04 End Bearing 5 4 77 50141W 05 Spring Washer M8 6 4 77 50141W 06 Screw M8 25 7 2 77 50141W 07 Gasket 8 1 77 50141W 08 Clutch Handle 9 1 77 50141W 09 Seal 10 1 77 50141W 10 Spring Washer 11 1 77 50141W 11 Gear Ring 12 1 77 50141W 12 Retaining Screw 13 1 77 50141W 13 Gear Ring input intermediate 14 1 77 50141W 14 Gear Carrier Assy output 15 1 77 50141W 15 Gear Car...

Page 20: ... 50141W 22 Seal Ring 23 1 77 50141W 23 Drum Assy 24 1 77 50141W 24 Screw 25 1 77 50141W 25 Cable Anchor Item Quantity Part Number Description 26 1 77 50141W 26 Screw 27 1 19 52132 96 Synthetic Rope 28 1 77 50141W 28 Brake Shaft Assy 29 2 77 50141W 29 Tie Bar 30 1 77 50141W 30 Motor End 31 1 77 50141W 31 Solenoid Assy 32 1 77 50141W 32 Solenoid Bracket 1 33 1 77 50141W 33 Solenoid Bracket 2 34 2 77...

Page 21: ...nd Bearing 5 4 77 50141W 05 Spring Washer M8 6 4 77 50141W 06 Screw M8 25 7 2 77 50141W 07 Gasket 8 1 77 50141W 08 Clutch Handle 9 1 77 50141W 09 Seal 10 1 77 50141W 10 Spring Washer 11 1 77 50141W 11 Gear Ring 12 1 77 50141W 12 Retaining Screw 13 1 77 50141W 13 Gear Ring input intermediate 14 1 77 50141W 14 Gear Carrier Assy output 15 1 77 50141W 15 Gear Carrier Assy intermediate 16 1 76 50256BW ...

Page 22: ...nd Bearing 5 4 77 50141W 05 Spring Washer M8 6 4 77 50141W 06 Screw M8 25 7 2 77 50141W 07 Gasket 8 1 77 50141W 08 Clutch Handle 9 1 77 50141W 09 Seal 10 1 77 50141W 10 Spring Washer 11 1 77 50141W 11 Gear Ring 12 1 77 50141W 12 Retaining Screw 13 1 77 50141W 13 Gear Ring input intermediate 14 1 77 50141W 14 Gear Carrier Assy output 15 1 76 50251BW 15 Gear Carrier Assy intermediate 16 1 76 50251BW...

Page 23: ... End Bearing 5 4 77 50141W 05 Spring Washer M8 6 4 77 50141W 06 Screw M8 25 7 2 77 50141W 07 Gasket 8 1 77 50141W 08 Clutch Handle 9 1 77 50141W 09 Seal 10 1 77 50141W 10 Spring Washer 11 1 77 50141W 11 Gear Ring 12 1 77 50141W 12 Retaining Screw 13 1 77 50141W 13 Gear Ring input intermediate 14 1 77 50141W 14 Gear Carrier Assy output 15 1 76 50260W 15 Gear Carrier Assy intermediate 16 1 76 50260W...

Page 24: ... Spring Washer M8 6 4 77 50141W 06 Screw M8 25 7 2 77 50141W 07 Gasket 8 1 77 50141W 08 Clutch Handle 9 1 77 50141W 09 Seal 10 1 77 50141W 10 Spring Washer 11 1 77 50141W 11 Gear Ring 12 1 77 50141W 12 Retaining Screw 13 1 77 50141W 13 Gear Ring input intermediate 14 1 77 50141W 14 Gear Carrier Assy output 15 1 77 50141W 15 Gear Carrier Assy intermediate 16 1 77 50141W 16 Gear Carrier Assy input 1...