Bushranger DV-9TH User manual

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Warranty Statement
Kingsley Enterprises Pty Ltd ('Kingsley') warrants to the original purchaser that the
product sold or distributed by Kingsley identified below (the Product) will be free from
defects in materials and workmanship for the warranty period identified below
commencing on the date of purchase from Kingsley ('the Warranty').
Kingsley, will rectify any defect in materials or workmanship appearing within the
Warranty period by repairing or replacing the Product (at its option).
Kingsley reserves the right to determine whether the Product contains any defects in
materials or workmanship covered by the Warranty.
The benefits offered by this Warranty are in addition to your rights and remedies under
the Australian Consumer Law. 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.
How to make a warranty claim
A claim under the Warranty must be made within the Warranty period identified below,
which commences on the date of purchase from Kingsley. To make a Warranty claim,
the Product must be returned to the place of purchase together with proof of purchase
unless otherwise agreed by Kingsley.
Any costs incurred in making a Warranty claim or returning a Product to the place of
purchase are to be borne by the person making the Warranty claim unless otherwise
agreed by Kingsley.
Exclusions
Rope provided with the winch is not covered by this warranty, nor is the finish of the
product. This Warranty does not cover any defect or injury caused by, or associated
with improper installation or maintenance; unauthorised service, repair, modification
or alteration; unsuitable physical or operating environment; electrical supply; acts of
God; misuse, abuse or neglect; accidental damage, or other alterations or modifications
which affect the reliability or performance of the product not attributable to a defect in
materials or workmanship.

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Warranty Period
The period in which a defect must appear in a Kingsley Enterprises or Bushranger 4x4
Gear product if the customer is entitled to claim the warranty is 1 year for electrical
components and a lifetime for mechanical components from the date of purchase from
Kingsley.
The warranty against defects contained in this document replaces any other warranty
against defects or voluntary warranty given in relation to the products.
Kingsley Enterprises Pty Ltd
6A Brooks Road, Ingleburn 2565
New South Wales, Australia
Phone: [phone]
International: [phone]
Email: [e-mail]

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Vehicle Recovery Winch
Congratulations on the purchase of your Bushranger vehicle recovery winch. This
product has been designed to meet the specified applications (see limitations below in
‘Warning’) 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
1. It is highly recommended that prior to using this off road vehicle recovery device,
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 first 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 five (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 efficiency of performance or damage to the winch, rope and
mounting platform.
WARNING

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NOTE: This product is a very powerful machine. Treat with extreme
care and observe all caution and warnings (See ‘Warnings’on Page 3 of this
manual).
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 qualifications 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).
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).
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 leather gloves when handling the wire
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 fibre
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. The thermal
indicator LED in the remote will indicate red as a
warning.
Check that the clutch T-handle is in the “Engaged”
position during and after use.
Safety

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Remove the 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 insufficient 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 running,
stop the winch immediately and inspect
or return it for repair.
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.

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NOTE: Kingsley Enterprises Pty. Ltd. 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 fleet 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.
Load Rating
Load and speed varies according to how much rope is
on the drum. The first 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. (Refer to winch specifications Pages 28 –30).
For this reason, automotive winches are rated at their
first layer capacities.
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:
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.
All automotive winches are rated at S3 intermittent periodic duty.
Winching Principles

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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 influence 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
= the gross vehicle mass (GVM)
S
= the type of surface to be traversed
G
= the gradient to overcome
Surface Type
Surface Drag (S)
Gradient
Angle (θ)
Gradient (G)
Metal
0.15
5%
3°
0.06
Sand
0.18
10%
6°
0.11
Gravel
0.20
20%
11°
0.2
Soft Sand
0.22
30%
17°
0.3
Mud
0.32
50%
26°
0.44
Marsh
0.52
70%
35°
0.58
Clay
0.52
100%
45°
0.71

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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:
Where Wt: 3,000kg, S: 0.52 G: 0.71
RPF = (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.
Note: A gradient of 10% is a rise of one metre in ten metres (Height/Distance).

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Snatch Block
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 rate 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 100cm (40″) apart.
Tree Trunk Protector Strap
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.
Recovery Damper
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.
Using Accessories

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Winch Extension Strap
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.
Bow Shackles
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.
Preparation before Winching
1) Connecting the remote control
When connecting the remote control,
always keep the remote control free
from the winch, rope and fairlead.
Always disconnect the remote control
when not in use.
2) Disengaging the clutch
Lift the clutch T-handle up and turn it in
a 90° counter-clockwise direction to the
“Disengaged” position. The rope can
now free spool off the drum. Never
disengage the clutch while the rope is
under load.
Winching Procedures

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3) Pull the rope to the anchor point
Wear leather gloves when free spooling
the rope out from the drum. Pull out
enough rope to reach the anchor point.
Be careful to pull the rope under
tension.
4) Engaging the clutch
To engage, lift the clutch T-handle and
turn it in a 90° clockwise direction to the
“Engaged” position. Never engage the
clutch while the drum is rotating.
Anchor Point
When choosing an anchor point, select a firm point such as a tree, stump or rocks.
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 fleet angle between the centre of the anchor point and the wire rope
maintained at less than 15°. Always use a tree trunk protector strap to prevent
ring barking the tree and damage to the rope.
Winch Operation
1) Check the rope
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.
2) 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.

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3) Secure anchor point
It is very important that an anchor point
is strong enough to hold the load while
winching. Do not wrap the rope around
the load and back onto itself. Always
use a tree trunk protector strap to
ensure that neither the rope nor the
anchor point is damaged.
4) Setting the vehicle engine
The recovery vehicle engine should
be running to provide maximum
power to the winch. The transmission
should be set in neutral, hand brake
applied and wheels chocked or
vehicle anchored to prevent the
vehicle from moving.
5) Attach shackle and hook
Use a shackle to lock both ends of the
tree trunk protector and then attach to
the rope hook.
6) Begin winching
Keep tension on the rope to ensure it
winds onto the drum tightly and evenly
and does not sink into the lower layers.
Release Hand brake and continue pulling
until the vehicle is recovered.

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7) Secure vehicle
Once the vehicle is secured, wind the
remaining rope back onto the drum
tightly and evenly and secure the hook
firmly.
8) Disconnect remote control
Take remote control out of the socket
and store it in a safe, dry and easily
accessible place.
Precautions whilst winching
Make sure the rope is wound onto the
drum tightly and evenly. Allowing the
rope to become loosely wound can result
in binding, pinching and wedging
between layers, ultimately damaging the
rope, shortening its life and increasing
the risk of injury and failure under load.
Always keep clear of the winch, rope,
hook and fairlead while winching

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Keep winching area clear. Do not allow
people to remain in the area while
winching. Never step over a live wire
rope whilst under load.
Never guide a rope onto the drum
with your hand. Use the supplied hand
saver strap.
Avoid the remote control cord from
coming in contact with the rope, as
damage to the cord may result.
A winching operation requires extra
consumption of battery power, so
always maintain your battery set in a
good condition.
Thermal Sensor –Warning LED
The warning LEDs are shown on the remote control for DV-9TH, Seal 9.5TH and
DV-12TH automotive winch models.
Green LED illuminates when the winch is operating under normal working conditions.
Red LED illuminates when the winch is operating under abnormal working conditions.
Stop operation and allow winch to cool (Green LED).

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Cable-Out Cable-In
(Normal winching) (Abnormal winching)
Cable-in/Cable-out Operation
1).To “Winch or Cable - Out”, trigger → out
2).To “Winch or Cable - In”, trigger ← in
To stop winching, release the trigger.
Clutch Operation
The clutch allows rapid pay-out of the rope for hooking onto a load or anchor point
and is operated by a clutch T-handle.
The clutch T-handle must be returned to the “Engaged” position before winching.
1). To disengage, lift the clutch T-handle and turn it 90° in a counter-clockwise
direction to the “Disengaged” position. Rope can now free spool off the drum.
2). To engage, lift the clutch T-handle and turn it 90° in a clockwise direction to the
“Engaged” position.
OUT
IN
LED LIGHT
GREEN OUT
IN
LED LIGHT
RED

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3). If a clutch T-handle cannot be properly locked in the “Engaged” position, rotate
the drum to help the clutch device engage the gear train.
4). Wear leather gloves and use a hand saver strap when guiding the rope off the
drum.
5). Never disengage the clutch while the rope is under load.
It is highly recommended that installation is performed by an authorised technician,
familiar with this product.
Before using the winch, make sure all electrical components have no corrosion or
damage.
Mounting
．It is very important that the winch is mounted
on a flat and hard surface or mounting channel
or in a suitable 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.
(ENGAGED)
(DISENGAGED)
Installation

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For DV-9TH & SEAL 9.5TH models
．Four (4) M10 x 1.50 pitch 8.8 grade high tensile steel bolts (supplied) must be
used in order to sustain the loads imposed on the winch mounting.
．Two (2) M12 x 1.75 pitch 8.8 grade high tensile steel bolts (supplied) must be
used for fastening the Roller fairlead into the mounting channel.
．Two (2) M10 x 1.50 pitch 8.8 grade high tensile steel bolts (supplied) must be
used for fastening the Hawse fairlead into the mounting channel.
For DV-12TH model
．
Eight (8) M12 x 1.75 pitch 8.8 grade high tensile steel bolts (supplied) must be
used in order to sustain the loads imposed on the winch mounting.
．Two (2) M12 x 1.75 pitch 8.8 grade high tensile steel bolts (supplied) must be
used for fastening the fairlead into the mounting channel.
Torque Settings (Maximum)
M10 x 1.5 –8.8 Grade
44 N.m
M12 x 1.75 –8.8 Grade
76 N.m
Drain Plug Orientation
For DV-9TH & DV-12TH it is important that the rubber drain plug on the bottom
of the 12V motor is orientated to face down to the ground to allow for
effective drainage. If the winch is mounted in such a way that the plug is not
facing the ground, remove the 2 motor mounting bolts and rotate the motor to
have the plug facing down. Reinstall the bolts and tighten to 10Nm.
Note: The motor can only be rotated in 90° increments.
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.

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Wiring Diagram
Attach the black lead firmly to the negative (–)battery terminal and red lead to
the positive (+) battery terminal. The voltage drop for the winch motor must
not exceed 10% of the nominal voltage of 12V. For best performance, mount
the winch as close to the battery as possible.
It is highly recommended that a Battery Isolator or Relay is installed. The relay
should be switched at the vehicle ignition when the accessories are turned on.
The battery isolator/Relay must be rated to handle more than the winch’s
maximum amp draw under load. Consult a qualified automotive electrician for
supply and installation of a suitable devise.
Nut Fastening for Motor & Contactor
The nuts on the motor and contactor should be fastened to the specified
torque as outlined in the diagram below. Attempting to fasten the top nut
without locking the bottom nut could result in damage to the studs. Do not
tighten top nut without locking bottom nut.

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Rope Preparation
The rope supplied on the winch has been installed under a minimum load from
the factory. Prior to using the rope for the first 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 previous section “Winching
Procedures”(Page 10). 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).