AMERICAN SPORTSWORKS 200 LUTV Series User manual

200 SERIES LUTV WINCH KIT (15184)
800-643-7332
Procedure:
1
As illustrated below, this kit contains:
Bumper Removal - if necessary (figure 1)
• Remove the (4) nuts / bolts used to attach the bumper.
• Remove old bumper and set aside.
• Save the (4) bolts and nuts for re-use on the new winch bumper.
Fig. 1
THIS KIT IS USED ON OLDER STYLE 200 SERIES LUTV MODELS
Bumper Bolts
2Winch Bumper Installation (figure 3)
There are two styles of winch bumpers. Review yours to see if there is a flat plate with
two holes already welded vertically to the front of the bumper as shown in figure 2. If so,
you do not need to use the supplied fairlead bracket. If your bumper does not have that
plate, you must use the supplied fairlead bracket. Pass the (3) 5/16-18 x 1” long bolts
through the winch, the roller fairlead mounting bracket (if needed), and the bumper.
Install the nylon locking nuts and tighten to 18 lb ft. Once installed, the winch motor
housing should be toward the right and the vertical face of the roller fairlead mounting
bracket should be forward and pointing “up” (as viewed from the driver’s seat).
Pass the (2) M10 x 25mm long bolts through the roller fairlead and the roller fairlead
bracket’s vertical face whether it is welded or bolted variety. Install the flat washer, lock
washer, and nut. Tighten.
Page 1 of 4
15200 Rev. B
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NOT FOR USE
Older style 200 Newer style 200
Wear proper eye protection through the entire process to
avoid potential eye injuries.
WARNING
RISK OF SERIOUS INJURY OR DEATH
• Use wheel chock and set parking brake with unit raised
• Always use properly rated ramps or jack stands when
working under a raised vehicle. Never work under a
vehicle supported only by a jack
WARNING
winch mountable bumper
winch / fairlead
hardware
fairlead
controller
terminal covers
winch hook
stock hardware that ships with winch
not needed for this application
hook strap
fairlead bracket
winch
Winch Mountable Bumper Qty: 1
Winch Motor & Spool Qty: 1
Hand Held Winch Controller Qty: 1
Winch hook Qty: 1
Hook Strap Qty: 1
Fairlead Qty: 1
Fairlead Bracket Qty: 1
Winch / Fairlead bolts & nuts Qty: 5
Terminal Covers Qty: 4
Fig. 2
Fig. 3
only one side illustrated
(bolts mount on both left &
right side of fairlead)
flat washer
lock
washer
M10 nut
5/16 - 18
nylon lock nut
bumper bolts / nuts
fairlead mounting
bracket (15117-2)
winch
fairlead
M10 x 25 bolt
5/16 - 18 x 1”
bolt
winch bumper
TOOLS REQUIRED
Ratchet 16mm Socket 10mm Socket
8mm Socket ½” Socket ½” Wrench
12mm Wrench 17mm Wrench Drill Motor
3/8” Drill Bit 1” Flat Drill Bit Hydraulic Jack
Phillips Screwdriver 13mm wrench Jack Stands or Auto Ramps
bumper with welded
fairlead bracket

4
Fig. 7
Fig. 6
5Final Connections
• At the front mounted winch, connect the RED wire to the (+) terminal on
the winch using. Ensure that the connection is tight and
that the supplied protective rubber terminal cover is installed. Repeat this
process with the BLACK wire and the (-) terminal on the winch.
• Remove any excess slack from the lead wires by shifting towards the rear
of the vehicle within the underbody channel. Use care to ensure that
insulation does not become damaged or pinched.
• At the back of the vehicle, connect the RED wire to the (+) battery terminal
as indicated on the battery casing.
• Connect the BLACK wire to the (-) battery terminal as indicated on the battery
casing.
• Slack left in the storage tub should be covered in factory loom, any excess
wire outside of the loom should be pulled through Hole #2 and neatly tied
to the frame using the supplied tie wraps.
• Using the supplied adhesive backed hook & loop material, attach winch
control to seat tub.
Hand Held
Winch Controller
Front of Vehicle
16” Lead Wire
to Winch
Underbody Channel
Fig. 5
Hole #2
Winch to
Battery
Connection
Behind Drivers
Seat
3Winch Wiring Preparation (figures 4 & 5)
• Using the 3/8” Drill and 1” Flat Bit, (2) 1” holes will need to be drilled on
the unit in order to install the winch.
• Hole #1 is to be drilled on the seat tub surround towards the center and
near the floor. This hole will allow the winch controller to be mounted on
the surround and allow the excess wire to be stored inside the storage tub.
• Hole #2 is to be drilled on the rear backsplash just above the battery and
will create access for the winch power from the battery.
Page 2 of 4
• Leave approximately 16” of wire at the front of the vehicle to allow
adequate slack for attachment to the winch
Use caution to ensure that the wire insulation does
not become damaged when feeding through the
channel. Bare wires will ground to the frame and
cause shorting or possible damage to the battery.
NOTE
Winch Wiring Installation (figures 3, 4 & 5)
• Lay out the wiring harness such that the leads can be easily identified by
length prior to installation.
• Place unit on properly rated jackstands or automotive ramps to allow
access to the underbody channel. Secure vehicle with wheel chock and
parking brake before attempting to work under the unit.
• Feed all wires from the outside into the seat tub storage area thru Hole #1.
Once installed, the winch control should be resting on the floor of the unit.
• Feed all wires from inside the seat tub storage area thru Hole #2 in the rear
backsplash. This will allow wire access to the battery connection and
forward feed to the front mounted winch (refer to figure 3).
• Carefully route the long black and red pair of wires through the underbody
channel to the front of the vehicle (refer to figure 5).
15200 Rev. B
Fig. 4
Hole #1 in
Tub Surround
Front of Vehicle

Fig. 9
• Attachment point must be centered in the loop of hook and the safety clasp must be
fully closed (see figure 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.
• Place a rug or carpet over the wire rope span (approx 6’ from the hook) to help
absorb the force released if the rope breaks (see figure 9).
• Move the Clutch Control Knob to the “Engaged” position.
Fig. 8
Page 3 of 4
Fig. 6
Check your vehicle:
• Check the battery level to ensure it is fully charged
• Examine the wire rope. Do not use the winch if the wire rope is frayed,
kinked or damaged.
• Check the Winch electrical connections to ensure that they are tight and
clean.
• Put the vehicle transmission in NEUTRAL.
Prepare the Winch:
• IF the vehicle with the winch is to remain in place during the winch
operation, engage the parking brake and chock the wheels (chocks sold
separately).
• Use the hook strap to pull out the wire rope by moving the Clutch Control
Knob to the “Released” position by pulling it out and away from the winch
then rotating it 90 degrees (see figure 6).
Attach Winch to the Object:
• Attach to the object by using a pulling point, tow strap or chain.
Leave at least 5 full turns of wire rope on the drum.
WARNING
Do not wrap the wire rope around the object and hook
onto the wire rope itself. This will damage the wire
rope and object being pulled (see figure 7).
CAUTION
Basic Operation
Shaft
Pin
If the pin rests
in the groove in the drum
the clutch is engaged.
If the pin rests
on top of the end of the drum
the clutch is released.
Drum
End
Shaft
Pin
Drum
End
Fig. 7
15200 Rev. B
Fig. 6
6Hook Installation
• Straighten the bent leg on the cotter pin on the winch hook and remove the
cotter pin and clevis pin. Attach the winch hook to the wire rope loop as
shown in figure 6. Replace the cotter pin and bend the cotter pin leg back to
it’s original position.
cotter pin
wire rope loop
clevis pin
Hook Strap

7625 DiSalle Boulevard
Fort Wayne IN 46825
62194 Commercial Street
Roseland, LA 70456
Toll Free 800-643-7332
Fax [phone]
www.amsportworks.com 15200 Rev. B
Overwinding the wire rope into the roller guides can
jam the winch causing it to not release with the
twist knob.
CAUTION
Constant duty loading of the winch will overheat the
winch motor and may cause damage to both the winch
and the battery.
CAUTION
Additional Winch Information
• When finished pulling the load, add slack to the wire rope by reversing the
direction which will release tension and allow easy disconnection from the
hook.
• Duty Cycle: 5% - This winch is designed for intermittent use. The duty cycle
is the amount of time the winch can operate at its maximum capacity for a 15
minute period of time.
• 45 Seconds at max rated load
• 14 minute rest between winching at rated load
• Double line rigging can be utilized to reduce the winch load. Appropriate
pulley block (sold separately) is required for this technique.
• Wear ANSI approved safety gear including gloves, goggles and shoes.
• Entanglement may occur. Do not wear loose clothing or jewelry, as they may
get caught in moving parts. Restrain long hair.
• Do not lift items vertically
• Do not use to lift or move people
• Do not use vehicle to pull on the wire rope and assist the winch
• Disconnect battery cables before working on or near the wire rope, drum,
roller guides, or wire connections to prevent accidental starting
• Inspect the winch before each use. Cracks, bent parts, frayed or kinked rope
will weaken the integrity of the winch and may cause sudden failure. A
winch with damaged components or questionable wire rope must not be
used
• Do not exceed the rated load capacity of the winch
• Be aware of dynamic loading! Sudden load movement may briefly create
excess load causing product failure
• Do not release the clutch under load
• Do not place fingers through the hook. Fingers may get caught and
entangled in winch roller guide. Use supplied strap to hold hook
• Stay clear of the wire rope when under load. Standing in the direct line of the
wire rope or behind the winch while operating may cause serious injury or
death if the wire rope were to break or slip.
• Do not use a recovery strap to winch. Recovery straps are designed to
stretch and may suddenly break and spring back towards the operator
• Secure the load after moving. This winch is not equipped with a locking
mechanism
• Keep at least 5 full turns of wire rope on the drum. Connection to the drum is
not intended to sustain a full load.
• People with pacemakers should consult their doctor or physician before use.
Electromagnetic fields in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
WARNING THE FOLLOWING MAY CAUSE SERIOUS INJURY OR DEATH!
Contact American Sportworks Customer Service for questions
or problems that may arise with the assembly and starting of
this unit at 800-643-7332 or at amsportworks.com.
Page 4 of 4
• Briefly operate the control to ensure that the winch works properly.
• IN - button should retract the winch cable
• OUT - button should extend the winch cable
• If operation is reversed, the power connections to the winch may be
connected backwards. Correct the wiring before continuing with operation.
• Standing aside the vehicle, retract the wire rope and winch the item as
desired.
Wire Rope may slip or break causing serious injury
or death
WARNING
Do not retract the hook all the way back into the winch
roller guides as this will damage the roller and could
lodge the hook in the winch
CAUTION