Bushranger COVERT RWC100S User manual

OWNERS MANUAL
RWC100S |RWC100W

Congratulations on the purchase of your Bushranger vehicle recovery winch. Be
proud that this product has been designed and thoroughly tested in Australia to
meet the specied applications (see limitations in ‘Warnings & Safety’) and with
proper care and preventative maintenance, will give you years of trouble-free
operation. All information in this publication is based on the latest production
information available at the time of print. We reserve the right to make changes
without notice because of continued product improvement.
Your Bushranger winch has been designed to give safe and dependable service
if operated according to the instructions. Please read and understand this
manual before installation and operation of the winch. Careless winch operation
can result in serious injury or property damage.
When requesting information or ordering replacement parts, always give the
following information:
1. Winch model and voltage
2. Serial Number
3. Item. No. and Part Number
4. Part Description

TABLE OF CONTENTS
Warnings & Safety
Specications
Installation
Operational Checklist (Prior to use)
Winch Products/Accessories
Winching Principles
Winch Operation
Maintenance
Troubleshooting
Winch Assembly & Parts List
Warranty
1
3
5
9
10
11
14
20
23
24
30

Warnings
Safety
• Before use, ensure that you are familiar with all winching operations (winch speeds
& direction).
• In some cases, the operator of a winch may be required to have Qualications
according to applicable laws and ordinances.
• Check all safety and environmental conditions prior to and during use.
• Only use correctly rated rope. Inspect for damage and/or defects before use.
• Do not use an unsuitable hook or snatch block for rope.
• The operator must remain with the winch during operation.
• The winch duty rating is S3 (intermittent-periodic). See page 13.
• Do not use the winch as a lifting device or a hoist for vertical lifting and moving
people.
• Ensure that the winch is connected to the correct voltage (12VDC only).
1. It is highly recommended that prior to using this vehicle recovery winch, that users
undertake off road training including vehicle recovery. Recovering immobilised
vehicles is a potentially dangerous exercise and this winch is to be used with great
care.
2. The winch is rated at the rst layer of rope on the drum for intermittent periodic duty.
3. The winch is not to be used to lift, support or otherwise transport personnel.
4. A minimum of ve (5) wraps of steel wire rope and ten (10) wraps of synthetic rope
around the drum is necessary to support the rated load.
5. Keep clear of winch, rope, hook, and fairlead while operating.
6. Rope can break without warning. Always keep a safe distance from the winch and
rope while under a load.
7. Failure to adequately align, support, or attach the winch to a suitable mounting
base could result in a loss of efciency of performance or damage to the winch,
rope and mounting platform.
8. The winch can generate a huge amount of tension and force. Be aware of moving
parts and keep hands clear of the winch drum, as well as where the rope feeds
through the fairlead.
9. A fully charged battery and good electrical connections are essential for correct
operation of your winch. A 12V 650CCA (cold cranking amps) battery is the
minimum recommendation.
CAUTION
READ USER MANUAL BEFORE OPERATION OR INSTALLATION.
Do not operate or install without understanding these instructions
and having a working knowledge of winching techniques.
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 1

• Do not exceed the maximum line pull ratings shown in this manual. Shock
loads must not exceed these ratings.
• Pull from an angle below 15° in the horizontal plane to straighten up the
vehicle or load.
• Always use appropriate gloves when handling the winch rope.
• When winching, always use a recovery damper. Place over the rope in the
middle third of its length.
• A rope should be replaced if it shows signs of excessive wear, broken strands,
corrosion for wire rope and excessive abrasion or fused and melted bre for
synthetic rope or any other defects.
• If the winch fails to pull a load under normal conditions, manually stop the
operation, otherwise motor damage may occur.
• Check that the clutch handle is in the “Engaged” position during and after
use.
• Disconnect the wired remote control from the winch when not in use and
store in a safe, dry place.
• Do not wrap the rope around the load and back onto itself. Always use a tree
trunk or winch extension strap.
• Keep hands and clothing clear of the winch, rope, and fairlead opening.
• Never unplug the remote control when winching a load.
• To avoid insufcient power when winching a load, the vehicle should be
running and in neutral.
• Keep the remote control clear of the rope at all times.
• If noise or vibration occurs when operating, stop the winch immediately.
If there are any technical concerns speak to your place of purchase or
authorized dealer.
• The rope must be wound in an under-wound orientation only to ensure
correct brake operation.
• Always inspect the hook, latch and pin prior to use. Do not use if there are any
signs of excess distortion or bending.
• Ensure the pin of the hook is secured using a correctly installed split/cotter pin.
WRONG FITMENT CORRECT FITMENT
Overwound Underwound
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 2

Bushranger COVERT 10 Specications
Specications:
MODEL
DIMENSIONS
WEIGHT (FITTED)
RATED LINE PULL (1ST LAYER)
MOTOR
REMOTE CONTROL
ELECTRICAL CONTACTOR
GEARBOX
BRAKE
CLUTCH
ROPE
FAIRLEAD
FINISH
WATERPROOF RATINGS
WARRANTY
CERTIFICATIONS
RWC100S |RWC100W
583mm(L) x 171mm (W) x 202mm (H)
31.5kg | 43kg
10,000lbs (4,536kg)
4.0kW (5.3 HP)
Dual Connection Remote
Wireless - 30m range / Wired - 5m Lead
Bespoke Albright DC Contactor - 500Amp
2 Stage Planetary & 2 Stage Spur gear
Gearbox mounted 100% load holding proportional
friction brake
Rotating Ring Gear - Lift & Turn Handle
Electrophorus Pre Treated Black Satin Powder
Coated Finish
IP68 Winch Motor and Gearbox
Limited Lifetime Warranty
(7 Year Warranty on Electrical Components)
CE
4 HOLES
582.3mm
(23")
63.0mm
(2.5")
88.0mm
(3.6")
254.0mm
(10")
167.6mm (6.6”) 160.7mm (6.3”)
114.3mm
(4.5")
201.7mm
(7.9")
208.6mm
(8.2")
171.2mm
(6.74")
227.0mm
(8.9")
∅11(0.43")
9.2mm Diameter x 28m
Wire Rope
Stainless Steel 304 Roller
Fairlead
Black 10mm diameter x
28m Synthetic Rope with
Protective Sleeve
Two Position, Aircraft
Grade Aluminium Hawse
fairlead
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 3

WIRE
Layer kgs lbs Total rope on drum
(m)
Total rope on drum
(ft)
1 4536 10,000 5.5 18
2 3561 7849 12.2 40
3 2930 6460 19.8 65
4 2490 5489 28 92
SYNTHETIC
Layer kgs lbs Total rope on drum
(m)
Total rope on drum
(ft)
1 4536 10,000 5.1 16.7
2 3561 7849 11.4 37.4
3 2930 6460 18.6 61
4 2490 5489 26.7 87.6
5 2164 4771 28 92
LINE PULL COVERT LINE SPEED MOTOR CURRENT
lbs kgs ft/min m/min Amps
0 0 60.6 18.5 60
4000 1816 10.6 3.2 211
6000 2724 7.6 2.3 277
8000 3632 5.9 1.8 336
10,000 4540 3.9 1.2 393
4 HOLES
582.3mm
(23")
63.0mm
(2.5")
88.0mm
(3.6")
254.0mm
(10")
167.6mm (6.6”) 160.7mm (6.3”)
114.3mm
(4.5")
201.7mm
(7.9")
208.6mm
(8.2")
171.2mm
(6.74")
227.0mm
(8.9")
∅11(0.43")
4 HOLES
582.3mm
(23")
63.0mm
(2.5")
88.0mm
(3.6")
254.0mm
(10")
167.6mm (6.6”) 160.7mm (6.3”)
114.3mm
(4.5")
201.7mm
(7.9")
208.6mm
(8.2")
171.2mm
(6.74")
227.0mm
(8.9")
∅11(0.43")
Performance - 1st layer of drum
Performance - Pull by layer
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 4

Installation
It is highly recommended that installation is performed by an authorised technician.
The winch is provided with a range of bolts to suit different mounting options:
Note: Four (4) M10 x 1.50 pitch 10.9 grade high tensile steel bolts (supplied) must be
used in order to sustain the loads imposed on the winch mounting.
Winch mounting
• It is very important that the winch is mounted on a at and hard surface/mounting
channel or in a suitably rated winch-compatible bull bar to ensure the motor,
drum and gearbox housing are aligned correctly.
• The fairlead is not designed to mount to the winch directly.
• The rope must be wound in an under-wound orientation only.
• 4 x M10x35mm Hex Head bolts (for foot down installation)
• 2 x M10x50mm Button Head Bolts (for mounting Hawse Fairlead in foot forward
mounting – COVERT 10S only)
• 2 x M10x45mm Button Head Bolts (for mounting Roller Fairlead in foot forward
mounting – COVERT 10W only)
• 2 x M10x40mm Button Head Bolts (for mounting Hawse & Roller Fairlead in foot
down mounting)
• 6 x M10 Spring Washers
• 6 x M10 Flat Washers
• 4 x M10 Hex Nuts
• 2 x M10 Nyloc Nuts
Foot Down Installation Foot Forward Installation
Torque Settings (Maximum)
M10 x 1.5– 10.9 Grade 44 N.m
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 5

Gearbox Rotation
Important note:
DO NOT USE a Power Tool such as an impact driver. This may lead to the stripping
of bolt threads or heads of bolts.
The gearbox is preset at position ‘A’ which suits the majority of vehicle tments,
however the gearbox can be rotated in 22.5° increments to allow for the clutch handle
to be orientated to best suit the installation requirements.
Fitment guides for common vehicles are available via bushranger.com.au.
1. Loosen and partially remove the 4 x bolts (see important note and red arrows
below) that secure the two gearbox sections to the winch. DO NOT remove the
gearbox sections from the winch.
2. Rotate the two gearbox sections and bolts simultaneously (all moving parts
highlighted in grey) to achieve the target angle as highlighted below.
3. Reinstall and tighten all bolts to Max 19Nm with torque wrench.
A
H
G
F
E
D
C
B
L
K
J
I
O
NM
P
STEP 1 STEP 2
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 6

Important Note:
Motor Rotation
The orientation of the motor assembly is set to the most common position suiting
the majority of vehicle tments. The motor can be rotated to 5 positions in 45°
increments to allow for the repositioning of the assembly if there are clearance
issues.
Loosen and remove the 3 x bolts that secure the motor cover to the drum support.
(circled in red)
Loosen and partially remove the 2 x bolts that secure the motor to the drum
support. (circled in green)
Rotate the entire motor assembly (all moving parts highlighted in grey) on Drum
Support to the desired position, ensuring the motor seal reseats into the correct
position.
Reinstall motor bolts and motor cover bolts and tighten to 10Nm torque.
1.
2.
3.
4.
1
1
2
2
1
STEP 1 STEP 2
REVISIONS
REV DESCRIPTION DATE
P1
0.5
1:5
REMOVE ALL BURRS AND SHARP EDGES
PLEASE CONSULT KINGSLEY ENTERPRISES
ENGINEERING DEPARTMENT FOR FURTHER
CLARIFICATION IF REQUIRED
AS1554.4:2010 •
AS1789:2003 •
REFER TO THE FOLLOWING
STANDARDS FOR CLARIFICATION:
AS1100.101:1992 •
AS1100.201:1992 •
AS1101.3:2005 •
ALLDIMENSIONS
INMILLIMETRES
1/01/2001 -
Date:
Date:
-
01/01/2001 01/2001
Commencing:
Zinc Plated Trivalent
Chromate (8-12 microns)
1 OF 1
--
Model: Make:
-
60863.9
-
-
- - 00
KINGSLEY ENTERPRISES PTY. LTD.
Drawing No:
COPYRIGHT
Mass (g):
Part No:
Rev:
Date:
Drawn:
DO NOT SCALE
Checked:
Approved:
Third Angle Projection
Scale: Sheet Size:
ALL RIGHTS RESERVED. THIS DRAWING MUST NOT BE
COPIED OR USED FOR ANY PURPOSE WITHOUT THE
EXPRESS AUTHORITY OF KINGSLEY ENTERPRISES PTY. LTD.
Page:
Finish:
A3
Part Description:
Tolerances unless otherwise stated:
0 - 1000mm
1000 - 2000mm
2000 + mm
All Angles
1.0
2.0
0.5
UNLESS OTHERWISE INDICATED ALL
FILLET WELDS ARE 5MM IN SIZE
Position 2 Position 3
Position 1
DO NOT USE a Power Tool
such as an impact driver. This
may lead to the stripping of
bolt threads or heads of bolts.
REVISIONS
REV DESCRIPTION DATE
P1
0.5
1:5
REMOVEALL BURRS AND SHARP EDGES
PLEASECONSULT KINGSLEY ENTERPRISES
ENGINEERINGDEPARTMENT FOR FURTHER
CLARIFICATIONIF REQUIRED
AS1554.4:2010 •
AS1789:2003 •
REFERTO THE FOLLOWING
STANDARDSFOR CLARIFICATION:
AS1100.101:1992 •
AS1100.201:1992 •
AS1101.3:2005 •
ALLDIMENSIONS
INMILLIMETRES
1/01/2001 -
Date:
Date:
-
01/01/2001 01/2001
Commencing:
ZincPlated Trivalent
Chromate(8-12 microns)
1OF 1
--
Model: Make:
-
51869.9
-
-
- - 00
KINGSLEY ENTERPRISES PTY. LTD.
DrawingNo:
COPYRIGHT
Mass(g):
PartNo:
Rev:
Date:
Drawn:
DONOT SCALE
Checked:
Approved:
ThirdAngle Projection
Scale: SheetSize:
ALLRIGHTS RESERVED. THIS DRAWING MUST NOT BE
COPIEDOR USED FOR ANY PURPOSE WITHOUT THE
EXPRESSAUTHORITY OF KINGSLEY ENTERPRISES PTY. LTD.
Page:
Finish:
A3
PartDescription:
Tolerancesunless otherwise stated:
0- 1000mm
1000- 2000mm
2000+ mm
AllAngles
1.0
2.0
0.5
UNLESSOTHERWISE INDICATED ALL
FILLETWELDS ARE 5MM IN SIZE
REVISIONS
REV DESCRIPTION DATE
P1
0.5
1:5
REMOVEALL BURRS AND SHARP EDGES
PLEASECONSULT KINGSLEY ENTERPRISES
ENGINEERINGDEPARTMENT FOR FURTHER
CLARIFICATIONIF REQUIRED
AS1554.4:2010 •
AS1789:2003 •
REFERTO THE FOLLOWING
STANDARDSFOR CLARIFICATION:
AS1100.101:1992 •
AS1100.201:1992 •
AS1101.3:2005 •
ALLDIMENSIONS
INMILLIMETRES
1/01/2001 -
Date:
Date:
-
01/01/2001 01/2001
Commencing:
ZincPlated Trivalent
Chromate(8-12 microns)
1OF 1
--
Model: Make:
-
51869.9
-
-
- - 00
KINGSLEY ENTERPRISES PTY. LTD.
DrawingNo:
COPYRIGHT
Mass(g):
PartNo:
Rev:
Date:
Drawn:
DONOT SCALE
Checked:
Approved:
ThirdAngle Projection
Scale: SheetSize:
ALLRIGHTS RESERVED. THIS DRAWING MUST NOT BE
COPIEDOR USED FOR ANY PURPOSE WITHOUT THE
EXPRESSAUTHORITY OF KINGSLEY ENTERPRISES PTY. LTD.
Page:
Finish:
A3
PartDescription:
Tolerancesunless otherwise stated:
0- 1000mm
1000- 2000mm
2000+ mm
AllAngles
1.0
2.0
0.5
UNLESSOTHERWISE INDICATED ALL
FILLETWELDS ARE 5MM IN SIZE
Position 4 Position 5
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 7

Battery Recommendations
A fully charged battery and good connections are essential for the proper
operation of your winch. The minimum requirement for a 12 Volt DC battery is 650
cold cranking amps.
• Do not lean over batteries while making connections.
• The earth wire should be disconnected during installation.
Wiring Diagram
The Bushranger COVERT winch is supplied with the power cables pre-wired to the
winch and with a universal tment isolation switch.
Find a suitable location close to the vehicle’s battery to mount the isolation switch
utilising the supplied bracket.
Route the main positive (red) wire from the winch to the isolation switch and
then from the isolation switch to the positive battery terminal. Connect the main
negative (black) wire to the negative battery terminal.
Find a suitable location to mount the winch control plug, either in the bull bar
or within an easily accessible location within the engine bay, using the supplied
universal bracket.
Isolation Switch
Control Plug
Wireless
Receiver
(mounted to
winch)
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 8

Operational Checklist (Prior to Use)
It is important to check and prepare the winch after installation, to ensure
everything is correctly setup and ready for use.
Installation Checklist
• Check the operation of the isolation switch.
• Check the hand controller connections are functioning.
•Wired Connection: Connect the 5m lead from the hand controller plug to
the control plug (see page 15).
•Wireless Connection: Hold wireless button and await the green light (see
page 15)
• Test the Clutch Handle freespool mechanism. (See page 14)
•Rope Preparation (Wire & Synthetic)
Prior to using the rope for the rst time, it must be tensioned onto the drum
under load to ensure a tight and uniform wrap is achieved. A rope that is not
tensioned and wound tightly and evenly prior to use can be permanently
damaged since the outer layers of rope can draw down into the inner layers
leading to binding, pinching or wedging between layers.
One method for tensioning the rope onto the drum is to use the weight of
the vehicle on a slight incline to pull on the rope while spooling in. This can
be achieved by following the steps outlined in the following section “Winch
Operation” (Page 14). Prior to spooling in under this load, ensure the rope is
pulled out to leave the minimum amount of wraps on the drum (5 wraps for
wire rope and 10 wraps for synthetic rope).
Note: There is a red indicator mark on the rope identifying the maximum
available length.
• Place the hand controller, 5m lead, red isolation switch key, and these
instructions in the glove box (or alternate location in the vehicle cab)
together.
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 9

Optional Winch Products/Accessories
Snatch Block
RBS11
Tree Trunk Protector Strap
RTS11
Recovery Damper
61X05
A snatch block is an important aid to successful
winching and can be used to increase the pulling
power (or mechanical advantage) of a winch, or
change the direction of a pull.
Where a double line pull is used (i.e. where a snatch
block is used at the load or anchor point and the
winch rope is connected back to the vehicle), twice
the pull force is applied but the speed of recovery is
halved.
One snatch block can be used in an indirect pull
where the vehicle is limited due to unsuitable ground
or obstruction. In this instance, the pull on the load is
the actual line pull of the winch.
If more than one snatch block is used, they must be
located at least 1m (40″) apart.
A tree trunk protector strap is useful for connecting
a rope to almost any anchor point but is primarily
designed to prevent a tree from ring barking. The
tree trunk protector should be wrapped around the
chosen tree or anchor point as low to the ground
as possible and the two ends brought together and
joined with a bow shackle. The bow shackle then
becomes the recovery point to where the rope or
extension strap is joined.
A recovery damper is a safety device designed to
help eliminate the possibility of injury or property
damage in the event of a rope failure. Placed in the
middle third of a live rope, in the event of the rope
breaking, the damper can help absorb the energy
in the rope and reduce the likelihood of injury or
damage.
It is recommended to use Bushranger winch and recovery products that have
been designed and tested alongside this winch.
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 10

Winch Extension Strap
RSW05
Bridal/Equaliser Strap
Bow Shackles
58X01K | 58X02K
Used when your rope isn’t long enough to reach
the recovery anchor point, extension straps are
made from polyester webbing and come in
various lengths and load ratings to suit varying
recovery situations.
Designed to spread the load of the recovery
across two points on the vehicle requiring
assistance. Can be used in both Snatch Strap or
Winching recoveries.
Only bow shackles that are load rated should be
used for vehicle recovery. Load ratings are visible
on the shackle and will be in the form of WLL
(working load limit) or SWL (safe working load). The
shackles, or any other recovery equipment, used
should be sized correctly for the winching task.
Winching Principles
NOTE: Bushranger 4X4 Gear recommend that prior to using this recovery equipment,
users should undertake formal training from an accredited industry body in winch use
and vehicle recovery.
Calculating Fleet Angle
To obtain the best rope service,
the direction of pull should be
on a horizontal plane within ±15
degrees and perpendicular
to the centreline of the winch
drum within ±15 degrees. If the
eet angle is larger than the
recommended angles, incorrect
spooling may occur, resulting in
the rope loading onto one side
of the rope drum and possible
damage to the rope or winch.
15°
15°
15°
15°
15°
15°
15°
15°
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 11

Required Pulling Force
Your winch must be powerful enough to overcome the resistance caused by an
obstacle, such as moving water, mud, snow, sand or on a steep hill, as well as
pulling the vehicle’s full weight.
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 factors listed that have inuence on the line pull effect required to
recover the vehicle. The values and calculations in this section are approximate
and are for reference only.
a) Gross vehicle mass (GVM)
b) Type of surface to be traversed
c) Gradient to overcome
In recovery and loading, where the winch is used to pull something, the required
pulling force (RPF) can be calculated according to the formula:
RPF = (Wt X S) + (Wt X G)
Where: Wt
S
G
= the gross vehicle mass (GVM)
= the type of surface to be traversed
= the gradient to overcome
Surface Type Surface Drag (S)
Metal 0.15
Sand 0.18
Gravel 0.20
Soft Sand 0.22
Mud 0.32
Marsh 0.52
Clay 0.52
Gradient Angle (θ) Gradient (G)
5% 3° 0.06
10% 6° 0.11
20% 11° 0.2
30% 17° 0.3
50% 26° 0.44
70% 35° 0.58
100% 45° 0.71
Gradient
Distance
Height
θθ
For example, if a vehicle weighing 3,000kg is winched up an incline of 100% on a
marshy surface, the above formula would be used as follows:
Note: A gradient of 10% is a rise of one metre in ten metres (Height/Distance).
Where
RPF
Wt: 3,000kg,
= (Wt X S) + (Wt X G)
= (3,000kg X 0.52) + (3,000kg X 0.71)
= 1,560kg + 2,130kg
= 3,690kg of effect required to recover the vehicle.
S: 0.52 G: 0.71
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 12

Duty Cycle Ratings
Duty cycle ratings usually specify continuous, intermittent, or special duty (typically
expressed in minutes). The IEC (International Electrotechnical Commission) lists the
following ratings:
All automotive winches are rated at S3 intermittent periodic duty.
• S1 - Continuous duty
The motor works at a constant load for enough time to reach temperature
equilibrium.
• S2 - Short-time duty
The motor works at a constant load, but not long enough to reach temperature
equilibrium, and the rest periods are long enough for the motor to reach ambient
temperature.
• S3 - Intermittent periodic duty
Sequential, identical run and rest cycles with constant load. Temperature
equilibrium is never reached. Starting current has little effect on temperature rise.
Load Rating
Load and speed vary according to much
rope is on the drum. The rst layer of rope
on the drum delivers the slowest speed and
the maximum load. A full drum delivers the
maximum speed and the minimum load.
For this reason, automotive winches are
rated at their rst layer capacities
FULL DRUM
MAX. SPEED
MIN. LOAD
HALF DRUM
MED. SPEED
MED. LOAD
FIRST LAYER
MIN. SPEED
MAX. LOAD
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 13

Winch Operation
Clutch Operation
The unique proportional brake in the winch allows for effortless powering OUT under
NO LOAD, with no concern for damage occurring to the brake or motor. In most
circumstances powering out the rope may be quicker and easier than free spooling
by hand. However if you wish to use the clutch handle for freespooling, familiarise
yourself with the operation. The clutch handle either “Engages” the winch for
operation or “Disengages” the winch for free spooling of the rope. The clutch must
always be “Engaged” before operating the winch under power.
Powering Out (No Load)
The unique Proportional Brake in the Bushranger COVERT winch allows for effortless
powering OUT under NO LOAD, with no concern for damage occurring to the brake
or motor. In most circumstances powering out the rope may be quicker and easier
than free spooling by hand.
Powering Out (Under Load)
It is not recommended to power OUT the winch rope UNDER LOAD for longer than 30
seconds. Exceeding this time will cause high amounts of wear to the brake.
1) To disengage, lift and turn the clutch handle 90° in a clockwise direction to the
“Disengaged” position. The rope can now free spool off the drum.
2) To engage, turn the clutch handle 90° in a counter-clockwise direction to the
“Engaged” position.
3) If the clutch handle cannot be properly locked in the “Engaged” position, rotate
the drum to allow the clutch mechanism to engage the gear train.
4) Wear appropriate gloves and use a pull strap when guiding the rope off the drum.
5) Never disengage the clutch while the rope is under load. The clutch handle must be
returned to the “Engaged” position before winching.
Important notes before operating the winch
Engaged Disengaged
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 14

Cable-in/Cable-out Operation
Wireless Mode
Pairing of new Hand Controller
Activating Wireless Mode
Press and hold the Wireless Power Button for 3 seconds
to activate the Wireless Control.
The WIRELESS light will illuminate to indicate you are in
WIRELESS mode. To turn off, press and hold the Wireless
Power Button for 3 seconds until the WIRELESS light
turns off. The controller is also equipped with an automatic
power off function. If the hand controller is not operated
for 2 minutes it will turn off automatically to conserve
battery power.
To “Winch - Out”, Press and hold the “OUT” Button
To “Winch - In”, Press and hold the “IN” Button
To stop winching, release the button.
In the case a replacement winch hand controller is required;
1. Ensure the pre-connected hand controller and the winch power is turned off via the
isolation switch.
2. Turn on the hand controller to Wireless Mode by pressing the button for 3
seconds until the Wireless Light ashes green.
3. Press and hold the IN and OUT buttons simultaneously. Both the Wireless and Wired
lights will go solid. Continue to HOLD until both lights ash slowly.
4. Whilst still holding the IN and OUT buttons – Turn ON power to the winch via the
isolation switch.
5. Release the IN and OUT buttons. The Wireless and Wired lights will ash fast and
pairing is complete.
Changing battery in the Hand controller
The hand controller is paired to the winch as standard and will operate in wireless
mode immediately.
Wired Mode
The wireless hand controller can also be used in wired Mode. Connect the winch hand
controller cable to the control plug and the hand controller. When the cable is plugged
in, the “Wired” light will illuminate RED.
To replace the battery, remove the screws in the front
panel of the hand controller. Replace the A23 battery
and reassemble the hand controller. When reassembling
the hand controller, ensure that the rubber seal is aligned
and not pinched.
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 15

Basic Winching Process
Connect the hand controller either wirelessly
(see page 15) or via the control plug lead.
Always disconnect the hand controller when
not in use.
3) Turn on the Hand Controller
Lift and turn the clutch handle in a clockwise
direction to the “Disengaged” position.
The rope is now free to be unwound from
the drum by hand. Never disengage the
clutch while the rope is under load. Do not
disengage the clutch if powering out in Step 3.
Please note: The Bushranger COVERT winch can be
powered out under no load, and in most situations it
may be faster. Pay careful attention not to allow the
rope to become “over wound” on the drum when
powering out.
4) Disengage the Clutch (for freespool
operation)
Turn power ON to the winch via the red
isolation switch, located close to your
vehicles battery. Insert the red key and turn
90° to enable the electrical connection.
2) Turn on Power to the Winch
When choosing an anchor point, select a rm point such as a tree, stump or rocks. DO
NOT WRAP THE ROPE AROUND THE ANCHOR POINT AND BACK ONTO ITSELF. Always use
a tree trunk protector strap to prevent ring barking the tree and damage to the rope.
If using a winch to retrieve another stranded vehicle, the rescue vehicle is considered
the anchor point and should be made secure. The anchor point must be strong
enough to hold the gross weight of the vehicle and be positioned to keep the eet
angle between the centre of the anchor point and the wire rope maintained at less
than 15°.
1) Establish an Anchor Point
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 16

Before winching, ensure the rope is wound
on the drum evenly. If unevenly wound,
there is a possibility of damaging the rope
when under load. Visually check rope for
any signs of damage.
Lay a recovery damper or heavy blanket
over the rope in the middle third of its
length. If a rope failure occurs, the damper
can prevent the rope from whipping.
Use a shackle to lock both ends of the tree
trunk protector and then attach to the
hook.
Please note: The winch line is now live. Do not step
over or cross the rope.
7) Check the Rope
9) Use a Recovery Damper
8) Attach the Shackle and Hook
To engage, lift and turn clutch handle
in a counter-clockwise direction to the
“Engaged” position. Never engage the
clutch while the drum is rotating. The drum
may need to be rotated slightly by hand to
ensure proper engagement.
6) Engage the Clutch (if freespooled)
Wear appropriate gloves when handling
rope. Hold the Pull Strap and pull or power
out enough rope to reach the anchor point.
Keep tension on the rope when unspooling.
5) Pull or Power Out the Rope to the Anchor
Point
|BUSHRANGER COVERT VEHICLE RECOVERY WINCH
Page 17