Berger & Schroeter 31440 User manual

ATV/UTV
ATV/UTV
ATV/UTV
ATV/UTV ELECTRIC
ELECTRIC
ELECTRIC
ELECTRIC WINCH
WINCH
WINCH
WINCH
General
General
General
General Safety
Safety
Safety
Safety Precautions
Precautions
Precautions
Precautions
WARNING:
WARNING:
WARNING:
WARNING: FAILURE
FAILURE
FAILURE
FAILURE TO
TO
TO
TO READ
READ
READ
READ AND
AND
AND
AND FOLLOW
FOLLOW
FOLLOW
FOLLOW THE
THE
THE
THE SAFETY
SAFETY
SAFETY
SAFETY INSTRUCTIONS
INSTRUCTIONS
INSTRUCTIONS
INSTRUCTIONS IN
IN
IN
IN THIS
THIS
THIS
THIS OWNER
OWNER
OWNER
OWNER ’
’
’
’ S
S
S
S
MANUAL
MANUAL
MANUAL
MANUAL BEFORE
BEFORE
BEFORE
BEFORE INSTALLING
INSTALLING
INSTALLING
INSTALLING OR
OR
OR
OR USING
USING
USING
USING YOUR
YOUR
YOUR
YOUR ELECTRIC
ELECTRIC
ELECTRIC
ELECTRIC WINCH
WINCH
WINCH
WINCH COULD
COULD
COULD
COULD RESULT
RESULT
RESULT
RESULT IN
IN
IN
IN DAMAGE
DAMAGE
DAMAGE
DAMAGE TO
TO
TO
TO
YOUR
YOUR
YOUR
YOUR WINCH
WINCH
WINCH
WINCH AND
AND
AND
AND SERIOUS
SERIOUS
SERIOUS
SERIOUS OR
OR
OR
OR FATAL
FATAL
FATAL
FATAL INJURY!!
INJURY!!
INJURY!!
INJURY!!
C
C
C
Check all safety and environmental conditions prior and during use.
Before use, ensure that you are familiar with all winching performance and operation such as speed & direction.
A wire rope should be replaced if it shows signs of excessive wear, broken wires, corrosion or any other defects.
The winches duty rating is S3 (intermittent – periodic)
If the winch fails to pull a load under normal conditions, stop the operation within 30 seconds otherwise motor
damage may occur.
Ensure that the winch is connected to the correct voltage of 12VDC only.
Check that the freespool shifter is in the “ Engaged ” position during and after use.
Remove the remote control from the winch when not in use.
Do not wrap the wire rope around the load and back onto it self. Always use a strap to ensure that the wire rope does
not fray or kink.
Keep hands and clothes away from the winch, wire rope, and fairlead during operation..
Never unplug the remote control and battery leads when winching a load.
To avoid insufficient power when winching a load, the vehicle should be running and in neutral.
When winching a heavy load, lay a heavy blanket or jacket over the wire rope near to the hook end
If excessive noise or vibration occurs when running, stop the winch immediately and return it for repair.
OWNER'S GUIDE

The winch is rated for intermittent-periodic duty.
The winch is not to be used to lift, support or otherwise transport personnel.
A minimum of five (5) wraps of rope around the drum are necessary to support the rated load.
The rated line pull of the winch must be powerful enough to overcome the added resistance caused by
whatever the vehicle is stuck in.
Never operate the winch under water.
Operate the winch cable in and cable out at no load after a winch was ingressed by water.
CAUTION
CAUTION
CAUTION
CAUTION
CUT
CUT
CUT
CUT AND
AND
AND
AND BURN
BURN
BURN
BURN HAZARD
HAZARD
HAZARD
HAZARD
Failure
Failure
Failure
Failure to
to
to
to observe
observe
observe
observe these
these
these
these instructions
instructions
instructions
instructions could
could
could
could lead
lead
lead
lead to
to
to
to minor
minor
minor
minor to
to
to
to moderate
moderate
moderate
moderate injury.
injury.
injury.
injury.
To
To
To
To avoid
avoid
avoid
avoid injury
injury
injury
injury to
to
to
to hands
hands
hands
hands and
and
and
and fingers:
fingers:
fingers:
fingers:
•
•
•
• Always
Always
Always
Always wear heavy leather gloves when handling a wire rope.
•
•
•
• Never
Never
Never
Never let wire rope slip through your hands.
•
•
•
• Always
Always
Always
Always be aware of possible hot surface at winch motor, drum or wire rope during or after winch use.
CAUTION
CAUTION
CAUTION
CAUTION
Moving
Moving
Moving
Moving Parts
Parts
Parts
Parts Entanglement
Entanglement
Entanglement
Entanglement Hazard
Hazard
Hazard
Hazard
Failure
Failure
Failure
Failure to
to
to
to observe
observe
observe
observe these
these
these
these instructions
instructions
instructions
instructions could
could
could
could lead
lead
lead
lead to
to
to
to minor
minor
minor
minor to
to
to
to moderate
moderate
moderate
moderate injury.
injury.
injury.
injury.
•
•
•
• Never
Never
Never
Never apply load to hook tip or latch. Apply load only to the center of hook.
•
•
•
• Never
Never
Never
Never use a hook whose throat opening has increased, or whose tip is bent or twisted.

Winch
Winch
Winch
Winch &
&
&
& Roller
Roller
Roller
Roller Fairlead
Fairlead
Fairlead
Fairlead Mounting
Mounting
Mounting
Mounting
1. It is very important that the winch shall be mounted on a flat hard surface in order to make sure the motor, drum and
gearbox housing are aligned correctly.
2. If a different mounting plate is used, the thickness shall be 5 mm (3/16 ” ). If different hardware is used, it must be SAE
grade 8 minimum.
3. Four (4) included M8x 25L Grade 8.8 High Tensile Steel Bolts must be used for securing the winch on the mounting
plate in order to sustain the loads imposed on the winch mounting.
4. Two (2) included M8 x 20L Grade 8.8 High Tensile Steel Bolts must be used for securing the roller fairlead on the
mounting plate.
Solenoid
Solenoid
Solenoid
Solenoid Mounting
Mounting
Mounting
Mounting
1. It disconnects your winch from the power source when the vehicles is not in use
2. It should be mounted close to the battery and keep the location from all metal structures
If
If
If
If with
with
with
with control
control
control
control box
box
box
box (
(
(
( solenoid
solenoid
solenoid
solenoid in
in
in
in it
it
it
it )
)
)
)
''B +'' means to connect to the Positive +of Battery
''B-'' means to connect to the Negative - of Battery
''M +'' means to connect to the Positive +(red) of motor
''M-'' means to connect to the Negative - (white) of mtor

Handlebar
Handlebar
Handlebar
Handlebar Remote
Remote
Remote
Remote Control
Control
Control
Control Mounting
Mounting
Mounting
Mounting
Handlebar mounted trigger switch can be operated without removing your hand from the grip.
• It is recommended that the switch be installed on the left handlebar. A piece of electrical tape
around the handlebar will help prevent rotation of mount on the handle bar.
• Do NOT tighten over any hoses or cables .
Operation
Operation
Operation
Operation
Cable
Cable
Cable
Cable In
In
In
In and
and
and
and Out
Out
Out
Out
1). To determine “ Cable Out “ , turn to the “ Out ” position
2). To determine “ Cable In “ , turn to the “ In ” position
3). To stop winching, release the trigger level
Freespool
Freespool
Freespool
Freespool Funtion
Funtion
Funtion
Funtion
The freespool allows rapid pay-out of the wire rope for hooking onto a load or anchor points and is
operated by a freespool shifter located on the end of the winch.
1). To engage the freespool, turn the freespool shifter counter-clockwise to the “ Engaged ” position.
The winch is now ready for pulling.

2). To disengage the freespool, turn the freespool shifter clockwise to the “ Disengaged ” position.
Wire rope can now be free spooled off the drum.
Maintenance
Maintenance
Maintenance
Maintenance
Wire
Wire
Wire
Wire Rope
Rope
Rope
Rope Replacement
Replacement
Replacement
Replacement
Before installing a new wire rope, wrap the end of the wire rope with tape to prevent fraying. Wind the
wire rope on the drum by pull a force to keep the tension constant. Never use a wire rope of a different size
or material and only use aircraft grade wire ropes.
1). Disengage the freespool.
2). Spool the old wire rope, and then remove it from the drum.
3). Have horizontal roller and bolts apart from the roller fairlead, then place the replacement wire rope
through the roller fairlead throat, pass below the drum, and insert it into the hole on the drum core.
4). Use a hex wrench to tighten the screw downwards to secure the wire rope.
5). Tighten the horizontal roller and bolt of roller fairlead
6) . Wear leather gloves and use a strap when guiding the wire rope off the drum.
7). It is very important that the winch shall be mounted on a flat surface , with the wire rope feeding form
the bottom of the drum.
8) . To rewind wire rope on the drum correctly , it is necessary to keep a slight load on the wire rope while
cable in.
Lubrication
Lubrication
Lubrication
Lubrication
All moving parts in the winch are permanently lubricated at the time of assembly. Under normal conditions
factory lubrication will suffice. If re-lubrication is necessary after repair or disassembly use a marine type
grease.

Check
Check
Check
Check the
the
the
the System
System
System
System
Before using the winch, verify the following:
1) Wiring to all components is correct. All loose wires are tie wrapped tight.
2) There are no exposed wiring or terminals. Cover any existing terminal exposures with terminal boots,
heat shrink tubing or electricians tape.
3) Turn ATV key switch to ON position. Check winch for proper operation. The wire rope should spool in
and out in the direction indicated on the switch.
Know
Know
Know
Know your
your
your
your winch
winch
winch
winch
• Take time to fully understand your winch and the winching operation by reviewing the manual with your
winch.

Maintenance
Maintenance
Maintenance
Maintenance Schedule
Schedule
Schedule
Schedule
Carry out all inspections listed below on schedule and inspections are divided into Daily, Monthly and 3
Monthly. Clean all connections because corrosion on electrical connections will reduce performance or may
cause a short.
Classification of check
Item
Item
Item
Item
Checking
Checking
Checking
Checking method
method
method
method
Checking
Checking
Checking
Checking reference
reference
reference
reference
Daily
Periodical
One
month
Three
month
*
Complete winch
Operate the winch in
and out
Minimum corrosion of
the internal motor
components
*
Installation
Mounting bolts &
alignment.
Bolts tension & wear.
Tightened and aligned
*
Remote
control
Working
Manual
Reasonable actuation
*
Wearing in contact
points
Visual.
Free of wear or damage.
*
Wire rope
Broken strands
Visual, measuring
(monthly )
Less than 10%
*
*
Decrease in rope
diameter
Visual, measuring
(monthly )
7% of nominal diameter
max
*
Deforming or corrosion
and fastening condition
of end
Visual
No existence
of abnormalities
*
Freespool
Wear in spring
Visual evidence of wear
Free of wear or damage.
*
Motor
Staining, damage
Visual evidence of wear
No existence of
abnormalities
*
Brake
Wearing of lining
Visual evidence of wear
Free of wear or damage
*
Performance
Visual
Reasonable actuation
*
Gear train
Damage, wearing
Visual evidence of wear
Free of wear or damage
and
distortion.

Trouble
Trouble
Trouble
Trouble Shooting
Shooting
Shooting
Shooting
When the winch fails to operate after several attempts, or if there is any fault operation while winching,
check followings.
Symptom
Possible Cause
Remedy
Winch will not operate
Cut circuit or loosing
Check battery cable.
Weak battery or insufficient power
Recharge or replace battery
Damaged over load protector
Replace over load protector
Loose connection of wirings
Checking all wirings
Damaged or stuck solenoid
Replace solenoid
Defective remote control
Check winch operation with an
auxiliary switch
Damaged motor or worn carbon brush
Replace motor or carbon brush
Motor runs in one direction.
Broken wiring or bad connection
Reconnect or replace wiring
Damaged or stuck solenoid
Replace solenoid
Switch inoperative
Replace switch
Dropt or lost wiring
Replace wiring and tighten.
Drum will not freespool.
Freespool not disengaged
Engaged freespool
Damaged brake or freespool ass ’ y
Replace brake or freespool ass ’ y
Damaged drum bushing
Replace drum bushing
Damaged gear box
Replace gear box
No brake
Damaged or inoperative pressed spring
Replace pressed spring
Disengaged freespool
Engaged
Damaged output shaft
Replace output shaft
Damaged 1st shaft
Replace 1st shaft
Brake distance is too long
Worn or damaged brake
Replace or adjust brake
Winch runs opposite direction
Motor leads crossed
Reverse electrical connections to
motor
Solenoid control crossed
Reverse black and red wires on the
solenoid
Remote control or trigger switch
crossed
Reverse electrical connections
Motor runs extremely hot
Long period of operation
Stop operation to have it cooled
Over-load
Reduce load
Damaged or inoperative brake
Replace or repair brake