Buyers Products Company 5571200 Service manual

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Installation Instructions
5579500 & 5571200
Electric Winches
WARNING
To prevent serious injury, read and understand all warnings
and instructions before use.
—continued inside
UNPACKING
When unpacking, check to make sure all parts are
included. Refer to Assembly Drawings and Parts Lists.
If any part is missing or broken, please call your local
distributor where you bought the winch from as soon as
possible.
SAFETY WARNINGS & PRECAUTIONS
When using this winch, safety precautions should
always be followed to reduce the risk of personal injury
and damage to the winch.
LEARN TO USE THIS WINCH:
After winch has been installed, take some time and
practice using it so you will be familiar with ALL
OPERATIONS. Periodically check the winch installation to
ensure that all bolts are tight. To ensure proper operation,
carefully inspect for any damaged parts before operating
the winch. Any damage part should be properly repaired
or replaced by identical parts by a qualified technician.
KEEP WINCHING AREA CLEAR:
Do not allow people to remain in the area during winching
operations. Do not step over a taut wire rope or allow
anyone else to do so. Due to the possibility of a cable
breaking,direct all persons to stand clear of any possible
pathways. A snapped cable could cause winch failure,
injury or death. Keep proper footing and balance at all
times. Do not reach over or across the winch and/or wire
rope while the winch is in operation.
INSPECT WIRE ROPE & EQUIPMENT FREQUENTLY:
The wire rope should be inspected for damages that can
reduce its breaking strength. A frayed rope with broken
strands should be replaced immediately. Always replace
the rope with part number 3025776.
WORKING AREA CONDITIONS:
Keep the working area well lit. Do not use this winch in
the presence of flammable gases or liquids.
KEEP CHILDREN AWAY:
Keep children away from working area, Never let children
operate the winch.
USE LEATHER GLOVES:
When handling or rewinding wire rope, always use hand
protection to eliminate the possibility of cuts caused by
burrs or broken strands.
DRUM ROPE:
Always make sure that there are at least 5 complete turns
of rope left on the drum before winching.
KEEP HANDS AND FINGERS CLEAR OF WIRE ROPE
AND HOOK WHEN OPERATING WINCH:
Never put your finger through the hook when reeling in
the last few feet. If your finger gets trapped in the hook
or rope, you could lose it. Never guide a wire rope under
tension onto the drum with your hand.
NEVER HOOK THE ROPE BACK ONTO ITSELF:
Hooking the rope back onto itself creates an
unacceptable strain, breaking individual strands, which in
turn weakens the entire wire rope.
KEEP PULLING DURATIONS AS SHORT AS
POSSIBLE:
The winch is designed for intermittent use and cannot be
used in constant duty applications. Do not pull more than
one minute at or near rated load. If the motor becomes
too hot to touch, stop and let it cool off for a few minutes.
If the motor stalls, cut off the power immediately.
DO NOT OVERLOAD:
Always use this winch at its rated capacity for your safety
and for better performance. Do not use inappropriate
attachments in an attempt to exceed its rated capacity.
AVOID CONTINUOUS PULLS FROM EXTREME
ANGLES:
This will cause the rope to pile up at one end of the drum.
When feasible, get the rope as straight as possible to the
direction of the object.

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NEVER OPERATE THE WINCH WITHOUT INSTALLING
THE ROLLER FAIRLEAD :
Operator injury or winch damage can result if a fairlead is
not installed.
STAY ALERT:
Watch what you are doing. Use common sense. Do not
use this winch when you are tired, stressed or WHEN
UNDER THE INFLUENCE OF DRUGS, ALCOHOL OR
MEDICATION.
DISCONNECT SWITCH:
Unplug switch when not in use.
REPLACEMENT PARTS & ACCESSORIES:
When servicing, use only Buyers Products replacement
parts. Use of any other parts will void the warranty.
WINCH WARNINGS & PRECAUTIONS
1. Keep hands and body away from Fairlead (cable intake
slot) when operating.
2. Secure vehicle in position before using winch.
3. Do not exceed winch load weight capacity (see
specifications on Page 8).
4. Make sure the winch is properly bolted to a structure
(or vehicle) that can hold the winch load.
5. Always use proper couplings when connecting winch
cable hook to load.
6. Do not lift items vertically. The winch is designed for
horizontal use only.
7. Do not use inappropriate attachments to extend the
length of the winch cable.
8. Never lift people or hoist loads over people.
9. Never come in between the winch and the load when
operating.
10. Do not apply load to winch when cable is fully
extended. Keep at least 5 full turns of cable on the reel.
11. After moving an item with the winch, secure the item.
Do not rely on the winch to hold it for an extended period.
12. Examine winch before using. Components may be
affected by exposure to everyday weathering, chemicals,
salts, and rust. Replace any worn or damaged parts
before using winch.
13. Never fully extend cable while under load. Keep 5
complete turns of cable around the winch drum.
14. When loading a boat onto a trailer without reel or
side hull rollers, make sure the trailer is submerged in the
water when the boat is loaded by the winch. Attempting
to drag the boat onto the trailer while on land can cause
winch failure and possible injury.
15. Never operate winch if cable shows any signs of
weakening, is knotted or kinked.
16. Winch does not have a locking mechanism. Secure
load after moving.
17. Do not cross over or under the cable while in use.
18. Do not move vehicle with cable extended and
attached to load to pull it. The cable could snap.
19. Use wheel chocks when parking the vehicle on an
incline.
20. Do not hit the motor housing when the winch stalls or
stops during operation.
21. Re-spool cable properly.
INSTALLATION
NOTE: Depending on your level of knowledge regarding
electrical wiring, you may wish to have this procedure
performed by a qualified technician.
1. Select a mounting site: on front of vehicle, the bed of a
truck, trailer, or other suitable location
CAUTION
It may be required to use steel reinforcement plates
(not included), and/or to weld on additional bracing (not
included), depending on the desired mounting location.
Remember that the winch is designed for horizontal pull,
not vertical.
2. Mount the Roller Fairlead to the Mounting Frame (not
included) using hardware.
3. Mount Electric Winch to the Mounting Fame using
supplied hardware. (See Fig. 1)
Mounting Frame
Roller
Fairlead
Fig. 1
4. Mount Solenoid Assembly to the winch.
A. Solenoid assembly can be mounted on top of tie
bars or over the motor. Hardware for both options is
included (See Fig. 2)
B. When mounting solenoid assembly over the motor,
wrap plastic strap over bracket #32 and around the
motor. Clip extra material. This will help to better
secure solenoid assembly in this position.

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Solenoid
Assembly
Motor
Red
Red
Green
Green
Black
Black
Yellow
Red
Yellow
So
cket Cover
Battery
Ground wire
5. Electrical Connections (refer to Fig. 3)
A. Before wiring, pay attention to the color of the
motor terminals and power cable. Both are color
coded.
Solenoid Assy.
Motor End
Bearing Assy. Solenoid
Bracket
Fig. 2
Fig. 3
B. Connect 3 short cables(coded red, black and
yellow) to the color coded terminals on the motor
accordingly.
C. Connect the red long cable from the Solenoid
Assembly to the positive battery terminal and the black
long cable to the negtive battery terminal at one end
and to the motor ground terminal at the other end.
D. Connect the black thin wire(ground wire) from the
Solenoid Assembly to the motor ground terminal.
E. Lift the Socket Cover and insert the plug of the
Switch Assembly(Remote Control). NOTE: Connecting
of the cables determines the winch operation
direction controlled by the push-buttons on the
Switch Assembly (Remote Control). After the winch
is mounted and powered, check the direction of the
Power In and Power Out on the buttons. If you wish
to change the direction on the Buttons, disconnect
the cable from the battery, switch the yellow coded
cable with the green cable. Then reconnect the
battery cables.
F. Disconnect the Switch (Remote Control) when not
in use.

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G. Disengage the clutch by turning the Clutch Handle
to the Disengaged position.(See Fig.4).
H. Pull the Cable through the Fairlead and connect the
Hook and Safety Pin. NOTE: The use of at least a 650
CCA battery is recommended.
CLOCKING INSTRUCTIONS (fig. 5)
The winch gear housing can be clocked in 8 different
positions. This enables the user to locate the clutch
handle at one of 8 equally spaced points (0, 45, 90, etc.).
The winch is preset at 0.
DISENGAGED POSITION
ENGAGED POSITION
CLOCKING POSITIONS: 0° and 60°
Fig. 4
1. Remove (2) M8x25 Tie Bar screws that attach the Gear
Housing Assembly to the Rope Drum.
2. Separate the Gear Housing Assembly w/clutch handle
from the Tie Bars.
3. Remove (8) M4x12 End Bearing screws.
4. Separate the End Bearing from the Gear Ring
5. Reposition End Bearing on the Gear Ring at desired
angle (clocked position).
6. Replace (8) M4x12 End Bearing screws. Torque to 2
ft-lb.
7. Align Drive Shaft, Drum Gear, and Tie Bars with Gear
Housing Assembly and reconnect.
8. Replace (2) M8x25 Tie Bar screws. Torque to 18 ft-lb.
WINCHING OPERATION
1. Disengage the clutch by moving the Clutch Handle to
the DISENGAGED position.
2. Grab the Cable Assembly hook with Hand Strap and
pull the cable to the desired length, then attach to item
being pulled.
CAUTION
Always leave at least 5 turns of cable on the drum. Review
winch safety warnings and precautions on pages 1 and 2
before continuing.
3. Re-engage the clutch by moving the Clutch Handle to
the ENGAGED position.
4. Lift the Connector Cover on Solenoid Assy. exposing
the electrical switch connector.
WITH WIRED REMOTE CONTROL (fig. 6)
Fig. 5
Fig. 6
1. While standing aside of the tow path, push the button
on Remote Control forward and backward (Fig. 7 and Fig.
8) to check winch running directions. Wait until the motor
stops before reversing directions.

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CAUTION
Do not POWER winch OUT for more than 10 seconds at a
time as this may cause damage to the brake system
CAUTION
It is important to make sure the winch is mounted on a flat
surface so the 3 major sections of the winch (the motor
end, the cable drum and the gear housing end) are properly
aligned. Run the vehicle engine during pulling operations to
keep the battery charging. When pulling a heavy load, place
a blanket or the similar over the cable 5 to 6 feet (1.5m to
1.8m) from the hook.
Fig. 7
Fig. 8
2. When the pulling is complete, rewind the cable onto
the drum. The cable must be rewound on to the drum
under a load of at least 500lbs. lf this precaution is not
taken, inner wraps will damage winch cable.
3. Remove the Switch Assy. from the Female Connector
and replace the Connector Cover.
WIRELESS REMOTE CONTROL (fig. 9)
(Accessory Part No. 5571000)
Fig. 9
1. Install and connect the Solenoid Assembly to the
winch and battery properly. See Fig. 2.
2. Connect the Receiver to Solenoid Assembly (Fig. 9).
3. Activate the Remote by pressing and holding both
IN and OUT buttons on the Remote simultaneously for
4 seconds till the red LED on the Remote lights up and
stays on.
4. Press IN or OUT button to power in or power out as
operation required.
5. Deactivate the system by pressing and holding both
IN and OUT button for 4 seconds simultaneously till the
red LED in the Remote turns off if winching operation is
ended. NOTE: 1. The Remote can automatically turn off
in 2 minutes if no operation. 2. Mis-operation protection
If both IN & OUT button are pressed and held for 15
seconds, program will treat it as mis-operation, and
Remote will turn off automatically.
Replace Battery (fig. 10)
If the LED light on the Remote(transmitter) flashes during
operation, the battery is low and should be replaced.
1. Remove the 2 screws from the Remote(transmitter).
2. Separate the top and bottom covers of the
Remote(transmitter).
3. Replace the old battery
with a new one.
Battery: DC12V/23A
4. Join the top and bottom
covers with the rubber seal
sitting between properly.
5. Secure the Remote with
two screws.
Fig. 10

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Programing the Receiver to a replacement
Remote(transmitter)
Hand-held Remote (transmitter) is programmed in the
factory to communicate with the receiver. Under normal
circumstances, programming will not be necessary
unless a Remote has to be replaced.
1. Switch on Remote (transmitter), refer to Wireless
Winching Operation step 3.
2. Turn on the Receiver. Refer to Step 1 and 2 in Wireless
Winching Operation.
3. Press and hold IN or OUT button on Remote till red
LED flashing.
NOTE: The programming has to be completed within
5 seconds once the Receiver is turned on. If the
programming is not completed in 5 seconds, the Receiver
will automatically reject programming. The Receiver
has to be turned off and to be restarted. Repeat the
programming procedure as described above.
LUBRICATION
1. All moving parts within the Electric Winch have been
lubricated using high temperature lithium grease at the
factory. No internal lubrication is required.
2. Lubricate Cable Assembly periodically using light
penetrating oil.
CABLE ASSEMBLY REPLACEMENT
1. Move Clutch Handle to DISENGAGED position.
2. Extend Cable Assembly to its full length. Note how the
existing cable is connected to the inside of the drum.
3. Remove old Cable Assembly and attach new one.
4. Rewind Cable Assembly onto cable drum being careful
not to allow kinking.
NOTE: Performance of this winch may vary depending on
variations of vehicle and/or battery power.
WARNING
The warnings, cautions and instructions discussed in this
instruction manual cannot cover all the possible conditions
and situations that may occur. It must be understood by the
operator that common sense and caution are factors that
cannot be built into this product, but must be exercised by
the operator.
TOP LEVEL PARTS
P/N Description Item Number
5579500 Electric Winch, 9500 Lb —
5571200 Electric Winch, 12000 Lb —
ACCESSORY PARTS
P/N Description Item Number
5571000 Wireless Remote —
5571001 Guide Roller —
5571002 Shackle, 3/4" —
5571003 Universal Mount 44
5571004 Jeep Mount —
5571005 Receiver Mount —
5571006 Handheld Controller, 30ft. cord —
ASSEMBLIES & KITTED SERVICE PARTS
P/N Description Item Number
3025773 Solenoid Assembly 31
3027944 Solenoid Mounting Bracket &
Hardware Kit
32, 33 ,34, 35 ,36, 37, 38, 39, 40,
41 ,42 ,43
3027945 Gear Ring Assembly, 9500 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,
14, 15, 16, 17, 18, 19
3027946 Gear Ring Assembly, 12000 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,
14, 15, 16, 17, 18, 19
3027947 Clutch Handle Kit 8, 9, 10, 12
3027948 Drum Assembly 23, 24, 25, 26
3027949 Cable Anchor Kit 24, 25, 26
3027950 Gasket & Seal Kit, All 7, 9, 20, 21, 22
3027951 Hardware Kit, All 2, 3, 5, 6, 10, 12, 24, 25, 26, 32, 33,
34, 35, 36, 37, 38, 39, 40, 41, 42,
43, 46, 47, 48
INDIVIDUAL SERVICE PARTS
P/N Description Item Number
3025772 Roller Fairlead 45
3025774 Solenoid —
3025775 Handheld Controller, 12ft. cord 50
3025776 Galvanized Cable, 3/8" x 100' 27
3025777 Slip Hook, Clevis, 3/8" 49
3025778 Motor, Universal 30
3025779 Brake/Shaft 28
3027952 Tie Bars 29
3027953 Hand Strap 51
3027999 Decal Sheet —
Complete Parts List

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Assembly Drawing and Parts List
Bill of Materials
ITEM QTY. DESCRIPTION
1 1 Dry Bearing
216 Screw M4*12
316 Spring Washer M4
4 1 End Bearing
5 4 Spring Washer M8
6 4 Screw M8*25
7 2 Gasket
8 1 Clutch Handle
9 1 Seal
10 1Spring Washer
11 1 Gear Ring
12 1Retaining Screw
13 1Gear Ring-input/intermediate
14 1Gear Carrier Assy-output
15 1 Gear Carrier Assy-intermediate
16 1 Gear Carrier Assy-input
17 1 Gear-input sun
18 1 Gear Bushing
19 1 Gear Box Cover
20 2 Spacer
21 2 Ring
22 2 Seal Ring
23 1 Drum Assy
24 1 Screw
25 1 Cable Anchor
26 1 Screw
ITEM QTY. DESCRIPTION
27 1 Cable
28 1 Brake/Shaft Assy
29 Tie Bar
30 1 Motor End
31 1 Solenoid Assy
32 1 Solenoid Bracket 1
33 1 Solenoid Bracket 2
34 2 Solenoid Bracket 3
35 2 Solenoid Bracket 4
36 5 Washer M6
37 5 Spring Washer M6
38 5 Screw M6*16
39 2 Washer M6
40 2 Spring Washer M6
41 2 Screw M6*12
42 2 Screw M5*16
43 2 Spring Washer M5
44 1 Mount Channel (Optional)
45 1 Roller Farilead
46 4 Washer
47 4 Spring Washer
48 4 Screw
49 1 Safety Hook
50 1 Switch Assy
51 1 Hand Strap
50 51
49
21
7
30 29
22
21
20
27 23
22
21
20
25
26
24
34568
910
11
12
13
14
15
16
17 18
7
19
3
2
28
44
45
48
47
46
31
32
40
41
39
33 35
36
37
34
38
36
37
38
42
43

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85579500INST Rev A
5579500
Features:
• Fast line speed
• Low amp draw
• Automatic load-holding brake
• Power In and Power Out
• IP68
5571200
Line Pull by Layer
Line Pull by Layer
Performance of 1st Layer
Performance of 1st Layer
CABLE
LAYER RATED LINE PULL
Lbs Kgs
19500 4310
27374 3348
36246 2836
45417 2459
54783 2171
SPECIFICATIONS: 5579500 5571200
Rated Line Pull 9500 lbs (4310 kgs) 12000 lbs (5445 kgs)
Motor(series wound) 12 VDC input power: 4.9 hp 12 VDC input power: 4.9hp
Gear Ratio 210:1 294:1
Gear Train 3-stage planetary
Drum 02.64"x8.35"(067mm x 212mm), hardened
Rope supplied Galvanized Cable 3/8" x 100'
Fairlead Roller fairlead
Hook 3/8"
Winch dimension 20.80" x 6.35" x 9" (528mm x 161mm x 229mm)
Mounting bolt pattern 10"x4.5"(254mm x 114.3mm)
CABLE
LAYER RATED LINE PULL
Lbs Kgs
112000 5448
29607 4362
38010 3637
46868 3118
56011 2729
LINE PULL LINE SPEED
MOTOR
CURRENT
Lbs Kgs Fpm Mpm Amp
0 0 21.0 6.4 86
2000 910 11.0 3.4 150
4000 1810 8.8 5.5 205
6000 2720 7.5 2.3 235
8000 3630 6.0 1.8 252
9500 4310 6.2 1.7 300
LINE PULL LINE SPEED
MOTOR
CURRENT
Lbs Kgs Fpm Mpm Amp
0 0 16.4 5.0 85
4000 1810 8.8 2.7 160
6000 2720 7.5 2.3 191
8000 3630 6.7 2.0 235
10000 4540 5.6 1.7 270
12000 5440 4.9 1.5 300
Spec Charts
)( 1
* height including solenoid assembly is 9"
.825
20.80
)( 002
7.86*
)( 452
10.00
)( 5.071
6.70 ØA
)( 061
6.30
)( 411
4.50
TROUBLE SHOOTING
SYMPTOM POSSIBLE CAUSE SUGGESTED REMEDY
Motor does not turn on
-Switch Assy. not
connected properly
-Insert Switch Assy firmly
to the connector
-Loose battery cable
connection
-Tighten nuts on cable
connectors
-Solenoid malfunctioning -Tap Solenoid to free
contact, applying 12V (for
12V motor) or 24V(for 24V
motor) to coil terminal
directly. Solenoid will make
an audible clicking when
activating.
-Defective Switch Assy -Replace Switch Assy.
-Defective motor -Check for voltage at
armature port with switch
pressed. If voltage is
present, replace motor
-Water has entered motor -Drain and dry. Run in
short bursts without load
until completely dry.
Motor runs too hot -Long period of operation -Let winch cool down
periodically.
Motor runs slowly or
without normal
-Battery with low charge -Recharge battery by
running vehicle engine.
power -Insufficient current or
voltage
-Clean, tighten or replace
the connector.
Motor runs but cable drum
does not turn
-Clutch not engaged -Push clutch Handle into
IN position. If that does
not work, ask a qualified
technician to check and
repair.
Motor runs in one direction
only
-Defective or stuck Sol
enoid
-Tap solenoid to free
contacts. Repair or replace
solenoid.
-Defective Switch Assy -Replace Switch Assy.
WARRANTY
Buyers Products Co. warrants all truck/trailer hardware manufac-
tured or distributed by it, to be free from defects in material and
workmanship for a period of two years from date of shipment.
Parts must be properly installed and used under normal conditions.
Any product which has been altered, including modification, mis-
use, accident or lack of maintenance will not be considered under
warranty. Normal wear is excluded. The sole responsibility of Buyers
Products Co. under this warranty is limited to repairing or replacing any
part or parts which are returned, prepaid, and are found to be defective
by Buyers Products Co. Authorization from Buyers Products Co. must
be obtained before returning any part. No charges for transportation
or labor performed on Buyers’ products will be allowed under this
warranty.