4x4 TOUGH 15-6068 User manual

4WD ACCESSORIES
4WD WINCH
USER GUIDE
YEAR WARRANTY
AUS
AFTER SALES SUPPORT
www.4x4tough.com.au
[email protected]1300 883 104
MODEL: 15-6068 PRODUCT CODE: 6068 08/2015
1
CONTENTS
• 5454kg/12000LB Winch
• 1 Pair Gloves
• Control Box C.W Attached Cables
• Fairlead Roller
• Attachment Kit for Fairlead Roller
• Clevis Hook
• Hand Control (Battery Included)
• 1 Spare Alkaline 23A 12V Battery for Hand Control
• Cable to Connect Hand Control to Winch
• Safety Dampener Blanket
• Warranty Certicate
• User Guide
Version 2
June, 2015

..............................................................
Page
WARRANTY DETAILS ..............................................................................................3
REPAIR AND REFURBISHED GOODS OR PARTS NOTICE ..................................3
SAFETY PRECAUTIONS ..........................................................................................
..........................................................................................
4
WINCH OPERATION WARNINGS ............................................................................5
12V DC 4WD WINCH PARTS LIST ...........................................................................7
...........................................................................8
12V DC 4WD WINCH KIT 9
INSTALLATION .......................................................................................................10
12
OPERATION
............................................................................................................
............................................................................................................
11
5454KGS/12000LBS LINE PULL AND CABLE CAPACITY TABLE ........................12
............................................................................................................13
13
BATTERY REPLACEMENT ....................................................................................14
RECEIVER COMPONENT REPLACEMENT ..........................................................14
MAINTENANCE ......................................................................................................15
DISPOSAL ...............................................................................................................15
FAQ .........................................................................................................................15
12V DC 4WD WINCH PARTS LIST DIAGRAM
WINCHING PRINCIPLES
REMOTE HAND CONTROL OPERATIONS
2
......................................................................................................13
Contents
SPECIFICATIONS
ELECTRICAL CONNECTION

AFTER SALES SUPPORT
AUS Hotline Costs: Landline calls are free. Mobile costs are extra & are dependent
on carrier charges – please check charges with your mobile carrier.
MODEL: 15-6068 PRODUCT CODE: 6068 08/2015
1300 883 104
AUS[email protected], www.4x4tough.com.au YEAR WARRANTY
1
Repair and Refurbished Goods or Parts Notice
Unfortunately, from time to time, faulty products are manufactured which need to be returned to the Supplier for repair.
Please be aware that if your product is capable of retaining user-generated data (such as les stored on a computer hard
drive, telephone numbers stored on a mobile telephone, songs stored on a portable media player, games saved on a games
console or les stored on a USB memory stick) during the process of repair, some or all of your stored data may be lost.
We recommend you save this data elsewhere prior to sending the product for repair.
You should also be aware that rather than repairing goods, we may replace them with refurbished goods of the same type
or use refurbished parts in the repair process.
Please be assured though, refurbished parts or replacements are only used where they meet ALDI’s stringent quality
specications.
If at any time you feel your repair is being handled unsatisfactorily, you may escalate your complaint. Please telephone us on
1300 883104 or write to us at:
Natural Product Solutions Pty Ltd
Unit 3 60 Box Road, TAREN POINT 2229
Telephone: [phone]
Email: [email protected]
Website: www.4x4tough.com.au
Remote Control Battery Replacement Notice
Occasionally, during shipment the battery inside the remote control may experience some power loss. For this reason, a
replacement battery has been provided inside the re-sealable plastic bag. If, upon initial use of
the remote control power loss is experienced, please replace the battery with the spare battery
provided. Refer to Page 9. of the User Guide for detailed battery replacement instructions.
The product is guaranteed to be free from defects in workmanship and parts for a period of 12 months from the date of
purchase. Defects that occur within this warranty period, under normal use and care, will be repaired, replaced or refunded
at our discretion. The benets conferred by this warranty are in addition to all rights and remedies in respect of the product
that the consumer has under the Competition and Consumer Act 2010 and similar State and Territory laws.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a
replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You
are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not
amount to a major failure.
Warranty Details
12V DC 4WD Electric Winch
3

Please read all instructions carefully before use. Unless directions are followed physical injury
or property damage may result. Save these instructions for future reference.
Read the following carefully before attempting to operate your winch and keep the instructions for future reference.
1. Dress Properly:
•
Don't wear loose clothing or jewellery.They can get caught in moving parts.
• Always wear leather rigging gloves supplied in this kit when handling winch cable. Do not handle cable with bare
hands as broken wires can cause injuries.
• Non-skid footwear is recommended.
• Protective hair covering to contain long hair..
2. Keep a Safe Distance::
• Ensure that all persons stand well clear of winch cable and load during winch operation .1.5 times the cable length is
recommended.If a cable pulls loose or breaks under load it can lash back and cause serious personal injury or death.
• Don't step over the cable.
•
Draping the dampener supplied or similar object over the extended winch cable is recommended as it will dampen any
cable back lash.
• All onlookers should be kept away from the work area. .
• Keep proper footing and balance at all times..
3. Don't Abuse the Cable:
• Never carry the winch by the cable or yank it to disconnect it from the receptacle.
• Keep cable away from heat, oil and sharp edges.
4. Don't Overwork the Winch:
• If the motor becomes hot to touch, stop and let it cool for a few minutes.
• Don't maintain power to the winch if the motor stalls..
• Don't exceed maximum line pull ratings shown in the table. (Refer to ‘Line Pull and Cable Capacity Table’ - Page 13)
Shock loads must not exceed these ratings.
5. Avoid Unintentional Starting:
:
•To avoid accidental engagement of the winch, ensure your battery isolation switch has been activated after use;
Refer toInstallation section on Page 10 this manual.
6. Check Damaged Parts::
• Before using, check your winch carefully. Any part that is damaged should be properly repaired or
replaced by an authorised service centre.
7. Repairs to the Winch
•This product should only be repaired by a suitably qualified technician using genuine parts.
8. Respool the Cable:
• Leather gloves must be worn while respooling. To respool correctly, it is necessary to keep a slight load on the cable.
Hold the cable with one hand and the remote control switch with the other. Start as far back and in the centre as you
can. Walk up keeping load on the cable as the winch is powered in.
• Do not allow the cable to slip through your hand and do not approach the winch too closely.
• Cautiously spool in the cable under power, keeping hands clear of the fairlead roller to ensure the user is not
exposed tothe possibility of having their hand caught.
Warning: The use of any other accessory or attachment other than those recommended in the
Instruction manual may present a risk of personal injury and equipment damage.
4
This product complies with AS1418.2.
Safety Precautions

Read the following carefully before attempting to operate your winch and keep the instructions for future reference.
1. This winch is fitted with an in-built thermal overload to prevent damage. If the winch stops during operation turn
the winch off and allow it to cool before continuing.
2. The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pile up on one end of the
drum. If this happens, reverse the winch to relieve the load and move your anchor point further to the centre of the
vehicle. On completion of winching, unspool and rewind for a neat lay on the drum; refer point 14 below..
3. Store the remote control switch inside your vehicle where it wi ll not become damaged. Inspect it before you plug it in.
4. When ready to begin spooling in, plug in remote control switch with clutch disengaged. Do NOT engage clutch with
motor running.
5. Never connect the hook back to the cable.This causes cable damage. Always use a sling or chain of suitable strength.
6. Observe your winch while standing at a safe distance. Stop the winching process every metre or so to assure the
cable is not pulling up in one corner. Jamming the cable can break your winch.
7. Do not attach tow hooks to winch mounting apparatus.They must be attached to vehicle frame.
8. The use of a snatch block will aid recovery operations by providing a doubling of the winch capacity and a halving of
the winching speed, and the means to maintain a direct line pull to the centre of the rollers.When double loading
during stationary winching, the winch hook should be attached to the chassis of the vehicle.
9. Ensure rated "D" or bow shackles are used in conjunction with an approved tree trunk protector to provide a safe
anchor point. Always use shackles that comply with AS/2741 – 2002. A 4.7 Tonne shackle is recommended..
10. 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 .
11. All winches are provided with a Red Marking on the cable to identify that 5 cable wraps remain on the winch drum.
When this mark appears at the rollers, no recovery should be attempted beyond this marking..
12. Since the greatest pulling power is achieved on the inner most layer of your winch, it is desirable to pull off as much
line as you can for heavy pulls (you must leave at least 5 wraps minimum on the drum-red cable). If this is not practical
use a snatch block and double line arrangement.
13. Draping the dampener supplied or similar object over the extended winch cable is recommended as it will dampen any back
lash should a failure occur.
14. Neat, tight spooling avoids cable binding, which is caused when a load is applied and the cable is pinched between
other cable spools. If this happens, alternatively power the winch in and out. Do not attempt to work a bound cable
under load - free by hand.
15. Apply blocks to wheels of winching vehicle when vehicles are on an incline..
16. Battery:
• Be sure that the vehicle’s battery is in good condition. Avoid contact with battery acid or other contaminants.
• Always wear eye protection when working around a battery.
• Have the engine running when using the winch to avoid flattening the battery.
Winch Operation Warnings
5

17. Winch Cable:
• Be sure that the cable is in good condition and is attached properly.
• Do not use the winch if cable is frayed.
• Do not move the vehicle to pull a load.
• Do not replace the cable with a cable of lesser strength.
• The life of the cable is directly related to the use and care it receives. Following its first and subsequent uses, a
cable must be wound on to the drum under a load of at least 500lbs (230kg)or the outer wraps will draw into the
inner wraps and severely damage the cable during winching.The first winch use should be a familiarisation run
while in a relaxed, non-recovery situation. Spool out the cable until the red cable mark appears (about five wraps
on the drum), then rewind the cable on to the drum under a load of 500lbs (230kg) or more.This will slightly tension
and stretch the new cable and create a tight cable wrap around the drum. Failure to do so may result in cable
damage and reduced cable life..
• When the cable is replaced, be sure to apply Loctite, or an equal compound, to the cable clamp thread.Tighten the
clamp screw properly but do not overtighten. The Loctite will prevent loosening of the screw in arduous conditions.
Loctite 7471 Primer and 222 Threadlocker are recommended.
18. Do NOT attempt to exceed the Pulling limits of this winch.
19. Do NOT drive your vehicle to assist the winch in any way. Vehicle movement in combination with winch operation may
overload the cable, the winch itself or cause damaging shock loads.
20. Shock loads when winching are dangerous.A shock load occurs when an increased force is suddenly applied to the
cable. A vehicle rolling back on a slack cable may induce a damaging shock load.
21. The winch shown in this manual is solely for vehicle, non-industrial applications.
22. Do NOT use winch in hoisting applications due to required hoist safety factors and features.
23.
24.
Do NOT operate and spool under full load for over one minute continuously.
25.
After use, the winch will be hot. Do not submerge under water or drive through rivers or streams until the unit
has cooled down.The IP67 level of waterproofing does not cover the winch when it is hot.
IP67 relates tothe level of waterproofing of the unit.
IP67 covers the unit being submerged in water up to one metre for not more than 30 minutes.
Do NOT use the winch to lift, support or otherwise transport personnel.
Winch Operation Warnings (cont.)
NOTE:
The safety precautions and instructions discussed in this manual can't cover all possible
conditions and situations that may occur. lt must be understood by the operator that common
sense and caution are factors which cannot be built into this product, but must be applied by
the operator.
6

ITEM QTY DESCRIPTION
1 1 END HOUSING, ASSEMBLY
2 1 DECAL
3 10 SOCKET HEAD CAPSCREW
4 1 DETENT SCREW
5 1 O-RING SEAL
6 1 CLUTCH LEVER
7 2 GASKET
8 1 HEX SHAFT
9 1 SUN GEAR
10 1 CARRIER ASSEMBLY, STAGE 1
11 1 CARRIER ASSEMBLY, STAGE 2
12 1 THRUST BEARING
13 1 CARRIER ASSEMBLY, STAGE 3
14 1 RING GEAR
15 4 FLANGE HEAD CAPSCREW
16 1 DRUM SUPPORT, GEAR TRAIN
16A 1 DRUM SUPPORT, MOTOR
17 2 DRUM BUSHING
18 2 TIE ROD
19 1 DRIVE SPLINED W/RETAINING RING
20 1 DRUM ASSEMBLY
21 1 BUTTON HEAD CAPSCREW
22 1 BRAKE ASSEMBLY
23 1 WIRE ROPE TERMINAL KIT
24 1 WIRE ROPE ASSEMBLY
25 1 CLEVIS HOOK
26 1 MOTOR
27 3 BOOT, ELECTRIC TERMINAL
28 1 CABLE ASSEMBLY, ELECTRIC
29 1 HEX HEAD CAPSCREW
30 1 WINCH CONTROL
31 1 TO MOTOR FIELD (BLUE)
32 1 TO MOTOR FIELD (RED)
33 1 TO MOTOR FIELD (YELLOW)
34 1 TO POSITIVE (+) TERMINAL OF BATTERY
35 1 TO EARTH MOTOR
36 1 TO EARTH MOTOR
37 1 TO NEGATIVE (-) TERMINAL OF BATTERY
38 1 REMOTE CONTROL ASSEMBLY
39 1 FAIRLEAD ROLLER
4X4 Tough™ 12V DC 4WD Winch Parts List
7

4X4 Tough™ 12V DC 4WD Winch Parts List
1
2
3
5
4
6
7
8
9
10
11
12
13
14
15 16 A
18
17
27
26
28
29
22
23
24
25
20
19
17
7
16
38
30
36
37
39
34
33
32
31
35
21
8

4X4 Tough™ 12V DC 4WD Winch
Control cable
Clevis hook
Control box
Clutch lever
Gear box
Motor
Battery isolation switch
Fairlead roller
Remote hand control
9
Wiring connection point for wired hand control lead
Dampener
Pair of gloves

LUBRICATION INFORMATION
All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly.
Under normal conditions factory lubrication will suffice. Lubricate cable after each use using light penetrating oil.
Inspect for broken strands and replace if necessary. If the cable becomes worn or damaged it must be replaced.
CABLE INSTALLATION
It is recommended that if the cable needs to be replaced you engage a qualified technician to perform this task.
AUXILIARY ITEMS (notincluded)
As afurther safeguard, you may wish toconsider installing the following items:
•An additional isolation switch on the positive lead from your battery to avoid the possibility of malicious use by an
ill intentioned person.
•A second battery to avoid depleting the power of the battery that starts your vehicle, as the use of any winch
draws a considerable amount of power.
1. a) The winch is to be mounted into a suitable steel mounting frame using the 4 point foot mounting system in either
a horizontal or vertical plane.
b) It's 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.
c) Before commencing installation ensure the mounting facility being used is capable of withstanding the winch’s
rated capacity.
d) The fitment of winches and / or a frontal protection system may affect the triggering of SRS air bags. Check that
the mounting system has been tested and approved for winch fitment in the airbag equipped vehicle.
2. Should you wish to manufacture your own mounting plate, the dimensions below will assist. A steel mount plate
6mm thick is recommended. Fasteners should be steel high tensile grade 5 or better. A poorly designed mount
may void warranty.
3. The winch should be secured to the mounting with 3/8"UNCx1-1/4" bolts and spring washers provided.
4. The roller fairlead is to be mounted so as to guide the cable onto the drum evenly.
Installation
MOUNTING YOUR WINCH
15-6068 12V DC 4WD Winch - Dimensions
(Dimensions are in millimetres)
165
64
218 TO-CLEAR
548
Front viewTop view
170 254
224
114
124
160
device correctly will void any warranty. The manufacturer will not be held responsible for damage
caused to property or persons as a result of inadequate installation.
10

ELECTRICAL CONNECTION
For normal self-recovery work, your existing electrical system is adequate. A fully charged battery and proper
connections are essential. Run the vehicle engine during winching operations to keep battery charged.
.
Pay close attention to proper electrical cable connection as follows (refer to diagrams below):
1. Short red cable (A) with red jacket connecting to the red terminal (A) of the motor.
2. Short black cable with yellow jacket (B) connecting to the yellow terminal (B) of the motor.
3. Short black cable with blue jacket (C) connecting to the blue terminal (C) of the motor.
4. Thin black cable (Earth) connecting to bottom Earth Terminal of the motor.
5. Long black cable (1.8m)one terminal connecting tothe bottom Earth Terminal of the motor, and the
other terminal connecting to negative (-) terminal of the battery.
6. Long red cable positive
7. It is essential that the cables are correctly connected by an experienced person who understands the wiring
connection procedure. Incorrect wiring may cause the solenoid unit to cease operating.
In such cases new solenoid replacements are available for purchase.
(+) connecting to positive (+) terminal of the battery.
CAUTION:
1. Your battery must be kept in good condition.
2. Be sure battery cables are not drawn taught across any surfaces which could possibly damage them.
3. Corrosion on electrical connections will reduce performance or may cause a short.
4. Clean all connections especially in remote control switch and receptacle.
5. In salty environments use a silicone sealer to protect from corrosion.
T
Motor - Cable connections
erminal C (Blue)
Terminal A (Red)
Earth Terminal
Terminal
B (Yellow)
Control Box - Cable connections
To motor
(Blue)
To motor Terminal A (Red) To motor Terminal B
To motor
Terminal C
Earth Terminal
To motor
Earth Terminal
(Yellow) To positive(+)
terminal of
battery
To negative(-)
terminal of
battery
11

Note: This guide is recommended for average vehicle rolling loads. Some applications may require a larger winch
than indicated.
5454Kgs/12000LBS Line Pull and Cable Capacity Table
Layer of cable 1 2 3 4 5
Rated line pull
per layer
Lbs
Kgs
Cable capacity Ft.
M
12000
5454
16
4.9
9550
4332
36
11
8000
3629
61
18.6
6800
3084
90
27.4
6000
2722
100
30.5
6. To commence winching operation, start vehicle engine, select neutral in transmission
and maintain engine speed at idle.
7. Operate the remote control switch to IN or OUT until the vehicle has been retrieved.
Stop the winch regularly to ensure that the cable is winding onto the drum evenly.
SUGGESTION:
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 recognise the
sound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Soon you will gain confidence
in operating your winch and its use will become second nature to you.
Winch Operation
12
OPERATING:
1. Ensure the vehicle is secure by applying the parking brake or chocking the wheels.
2.
P
protector wrapped around a suitably sized tree which will not be damaged by the winching operation.
ull out the winch cable to the desired length and connect to an anchor point. A suggestion would be a tree trunk
The winch clutch allows rapid uncoiling of the cable for hooking onto the load or anchor point. The shifter tab located on
the gear housing of the winch operates the clutch as follows:
a)To disengage the clutch, move the clutch shifter tab to the DISENGAGE position. Cable may now be free spooled off the drum..
b)To engage the clutch, move the clutchshifter tab into the ENGAGE position. The winch is now ready for pulling..
3. Re-check all cable rigging before proceeding.
4
Plug in the winch remote hand control (see Page 10 for instructions). It is recommended that the winching operation
takes place from the driver's position to ensure safe operation.If using the wireless remote control always ensure
that you are located at a distance which is greater than 1.5 times the length of the exposed cable.
5. Turn the winch on by turning the on / off orange switch to the on position (clockwise)
•
•
•
•
•
•
•
Never winch
Check the winch carefully and thoroughly before operating.
with your vehicle in gear or in park. This would damage your vehicle's transmission.
Never wrap the cable around the object and hook onto the cable itself. This can cause damage to the object being
pulled, and kink or fray the cable.
Keep hands, clothing, hair and jewellery clear of the drum area and cable when winching.
Never use the winch if the cable is frayed, kinked or damaged.
Never allow anyone to stand near the cable, or in line with the cable while it is under load. If the cable
should slip or brake,it can suddenly whip back along the line of pull, causing a hazzard for anyone in the area.
Always stand well to the side while winding.
•
ALWAYS disengage the winch when not in use.
CAUTION:
OFF ON
OFF ON

Winching Principles
Y
ou need a winch to be powerful enough to pull your vehicle while overcoming the added resistance caused by obstacles, moving
wate
r, mud, snow, sand or inclines.
As a general guide you need a winch with a maximum line pull at least 1.5 times greater than the gross vehicle weight.
There are three
and are for reference onl
y.
1.
Gross Vehicle Weight (Wt): Contains a vehicle weight and the weight of the supplies and equipments carried.
2. Surface Drag (S):
The characteristics of the terrain or surface to be traversed.
SURFACE TYPE Metal Sand Gravel Soft Sand Mud Marsh
Surface Drag (s) 0.15 0.18 0.20 0.22 0.32 0.52
3.
Gradient resistance: The incline of grade or slope on which the vehicle is being moved.
A gradient of 10% is a rise of one metre in ten metres.
Gradient 5% 10% 20% 30% 50% 70% 100%
Angle (ref.) 30 60 110 170 260 350 450
Value of (G) 0.06 0.11 0.2 0.3 0.44 0.58 0.71
Rolling Pull E
ffect required=(Wt X S) + (Wt X G)
For example, if a vehicle weighing 2994 Kgs is winched by 100% on an o
ff road surface,
the above formula would be used as follows:
Wt: 2994 Kgs (gross vehicle weight)
G: 0.71 (gradient value of 100%)
(Wt X S)+ (Wt X G)
= 1557 Kgs + 2126 Kgs
= 3683 Kgs of e
ffect required to recover the vehicle
Rated Line Pull 12000Lbs (5443kgs) single line. Battery Leads 1.80m
Motor Series wound DC 12V with 6hp/4.5kw Fairlead 4-way roller fairlead
Gear Train output 3 stage planetary Wire Rope 9.5mmx26m
Gear Ratio 265:1 Drum Size 64mmx224mm
Clutch Sliding ring gear Dimensions 548mmx160mmx218mm
Braking Action Automatic in the drum NW. 38kg (84Lbs)
Battery Recommended 650 CCA minimum for winching Mounting Bolt Pattern 254mmx114.3mm
Line pull Lbs 0 2000 4000 6000 8000 9500
Kgs 0 907 1814 2722 3629 4310
Line speed FPM 25.6 16 11.9 9.79 8.01 5.9
MPM 7.8 4.88 3.63 2.98 2.44 1.8
Motor current
Amps 80 130 180 230 290 350
Remote Hand Control Operation
•Before commencing any operation with the winch using the remote hand control
ensure that the isolator switch on the side of the control box is in the OFF position.
•Plug the control cable (with the remote hand controller attached) into the socket on
the control box and turn slightly anti-clockwise to lock into position.
•Turn the isolator switchtothe ON position.
Note: It is recommended that for the initial set-up of the winch (prior to applying any load)
that the winch be operated in the WIRED mode.
•Once the winch has been set-up then the remote hand control can be operated either
in the WIRED ORWIRELESS mode.
•To use the remote hand controller in the WIRELESS mode unplug the remote hand
controller from the control cable.
•If at any stage during operation the remote hand controller fails to operate the winch,
reset the control box by turning the isolator switch off then back on.
• The hand control is not waterproof and care must be taken in its usage.
In the event of damage or breakage, replacement hand controls are available to be
purchased through the 4x4 Tough customer service helpline.
WIRELESS
ON/OFF switch
WIRELESS
LED indicator
WIRED
LED indicator
LED light
power ON/OFF
LED light
Cable engage/
disengage
13

Receiver Component Replacement
• To open control box unscrew 4
screws and carefully lift the lid.
Figure 7. Figure 8. Figure 9.
Receiver
component
• Gently lift out old Receiver Component (do not pull out by the wiring)
and unplug. Insert replacement Receiver component.
Control box
Battery Replacement
CAUTION:
• Keep battery out of reach of children.
• If achild swallows a battery seek medical advise immediately.
• Do not use any metallic devices to install battery -this may cause a short circuit.
• To open remote hand control unscrew 4
screws and carefully pull apart the two halves.
Battery
Figure 1. Figure 2. Figure 3.
Remote hand
control
•To access the battery, pull off the IN/OUT toggle switch assembly
which is inserted into the 6 recesses on the circuit board. Bend the
front of the printed panel forward. Once the battery is replaced
(ensuring the polarity orientation is correct.ie: Match+ to+),
put back the IN/OUT toggle switch assembly and reassemble the
hand control.
PLEASE CONTACT THE AFTER SALES SUPPORT TEAM IF REPLACEMENT PARTS ARE REQUIRED.
14
The hand control is supplied with a Alkaline 23A 12V battery within the hand control and a spare battery if
it requires changing.

Maintenance
FAQ
Q: How much rated line pull do I need?
A: Rated line pull refers to the maximum amount of weight that a winch can shoulder, so you need a winch with enough
strength to handle your vehicle's weight. Thankfully, there is a simple formula for calculating the correct rated line
pull: Gross Vehicle Weight x 1.5 = Minimum Rated Line Pull.
Q: Can I remove my winch?
A: Yes. During the off season, you can unbolt your winch and leave it at home. Some mounts make it easy to
remove the winch, and some require a bit more effort. Hitch mounts and grille guard mounts are the easiest since
the winch is so accessible. In a hidden, semi-hidden or replacement bumper setup, the winch sits behind or below
the bumper, so removal can be tricky.
Q: Can I operate my winch wirelessly?
A: Yes. While all winches come with a wired remote control, your 4X4 Tough Winch also operates wirelessly. With
maximum ranges of between 25 and 30 metres, Refer to the operating instructions on page 13 within this manual.
Q: What's the difference between electric and hydraulic winches?
A: The basic difference between an electric and a hydraulic winch is the power source. Electric winches link to the
vehicles battery, whereas hydraulic winches are driven from the power steering pump. Electric winches are the
most prevalent in the market place and as such greater choice is available. They have the advantage of being able
to operate without the vehicle running, however as they draw significant power from the battery it is recommended
the vehicle be running whilst winching operations are underway .Electric winches generate significant heat and it is
important they be run for only short periods of time before being rested to cool down. Hydraulic winches are able to
operate on a more continuous basis, however they can only operate if the vehicle is running.
15
It is highly recommended that the winch be used regularly (once a month). Simply power the cable out 15m, free
spool 5m and then power back in.This will keep all components in good working condition.
All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of
assembly. Under normal conditions factory lubrication will suffice. Lubricate cable after each use using light
penetrating oil. Inspect for broken strands and replace if necessary. If the cable becomes worn or damaged it
must be replaced.
CAUTION:
1. Your battery must be kept in good condition.
2. Be sure battery cables are not drawn taught across any surfaces which could possibly damage them.
3. Corrosion on electrical connections will reduce performance or may cause a short.
4. Clean all connections especially in remote control switch and receptacle.
5. In salty environments use a silicone sealer to protect from corrosion.
It is also recommended to have your winch serviced every 12 months to keep the unit in optimum working condition.
Your 4X4 Tough winch should only be serviced by qualified persons. Examples include, qualified mechanics,
auto electricians and engineers. The winch should be removed from the vehicle prior to beginning the service.
Please ensure geniune parts are used for any spare parts that may be required during the service.
Contact the customer service department on 1300 883 104 if necessary to obtain parts under warranty.
Photographs of faulty parts are recommended to support warranty claims.
Please email these to [email protected]
Disposal
• Please consider when disposing of electronic products such as a winch that some components can be recycled and
recovered for re-use. Do not attempt to dissemble any electronic product unless you are a trained
electronics technician.
• Many councils hold e-waste (electronic waste) collections. Contact your nearest council to enquire about the best
method of disposal in your area.

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4x4 TOUGH GO OFF ROAD is a trademark of
Natural Product Solutions Pty Ltd
Unit 3, 60 Box Road, Taren Point NSW 2229
Phone: [phone].
www.4x4tough.com.au | [email protected]