DK2 EW8020 Quick reference guide

EW8020
WINCH

1
Assembly & Operating Instructions
INTRODUCTION
Congratulations on your purchase of winch. We design and build winches to strict
specifications and with proper use and maintenance should bring you years of
satisfying service.
WARNING - Read, study and follow all instructions before operating this
device. Failure to heed these instructions may result in personal injury
and/or property damage.
Your winch can develop tremendous pulling forces and if used unsafely or
improperly could result in property damage, serious injury or death. Throughout
this manual you will find the following symbols for caution, warning and danger.
Pay particular attention to the notes preceded by these symbols as they are

2
written for your safety. Ultimately, safe operation of this device rests with you, the
operator.
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. This notation is also used to alert against unsafe
practices.
Indicates a potentially hazardous situation which, if not avoided
could result in death or serious injury.
INCLUDED WITH YOUR WINCH
DESCRIPTION QUANTITY
1. Winch Assembly with pulling strap 1
2. Power Cord/Switch Assembly (Sulpplied for prototype) 1
3. Control box 1
4. ATV Handlebar Switch 1
5．Mounting bolt kit 2
GETTING TO KNOW YOUR WINCH
Your winch is a powerful piece of machinery. It is important that you
understand the basics of its operation and specifications so that when you
need to use it, you can use it with confidence and safety. Below is a list of
the components of your winch and their use. Practices using your winch
before you are in a situation to need to use it.
CAUTION
WARNING

3
1. Motor: Your 0.8 hp motor is powered by a 12 volt battery and provides power to
the gear mechanism which turns the drum and winds the strap;
2. Winch Drum: The winch drum is the cylinder on which the pulling strap is
stored. It can feed or wind the strap depending on the remote winch switch.
3. Pulling strap: Your winch has a 1.6'(w) X2.4'(L) nylon strap designed
specifically for load capacity of 600lbs.
4. Mechanical Gear System: The reduction gears convert the winch motor power
into extreme pulling forces.
5. Braking System: Braking action is automatically applied to the winch drum
when the winch motor is stopped and there is a load on the strap. The braking
action is applied by a separate mechanical brake.
6. Control System: your winch is controled through a solenoid control box by
press button of the ATV power switch.
7. Solenoid: Power from the vehicle battery flows through the weather sealed
switch before being directed to the winch motor.
WINCH ASSEMBLY AND MOUNTING

4
Fixing Panel
(1.96')
Black Motor -
Red Motor +
(5.9')
OUT
IN
Red Battery +
Black Battery -
1. Your winch is designed with a bolt pattern that is special in this case use of the
winch. Proper alignment of the winch will allow even distribution of the full rated
load.
2. Connect the battery and motor leads as the drawing above every type of winch
is different each other.
CAUTION –Batteries contain gases which are flammable and explosive.
Wear eye protection during installation and remove all jewelry. Do not lean over
battery while making connections.
3. Check for proper drum rotation. Press the cable out button on the power
switch. If the drum is turning and releasing more strap then your connections
are accurate. If the drum is turning and collecting more strap then reverse the
leads on the motor. Repeat and check rotation.
SAFETY PRECAUTIONS

5
WARNING
WARNING –DO NOT EXCEED RATED CAPACITY.
WARNING –Intermittent use only.
WARNING - Do not use winch in lifting or moving or persons.
WARNING-Disconnect the remote control and battery leads
when not in use.
WARNING- Do not exceed maximum pull rating. Avoid “shock
loads” by using the control switch intermittently to take up the
slack in the strap. “Shock loads” can far exceed the rate
capacity for the strap and drum.
WARNING- Do not exceeds maximum line pull ratings shown
on the tables.
Do not use as a hoist. Do not use for overhead lifting.
Failure to heed these warnings may result in personal injury
and/or property damage.
CAUTION - If the motor stalls do not maintain power to the
winch. Electric winches are designed and made of intermittent
use and should not be used in constant duty applications.
CAUTION - Never release the free-spool clutch when there is a load on
the winch.
GENERAL TIPS FOR SAFE OPERATION
•The vehicle engine should be kept running during operation of the
winch to minimize battery drain and maximize power and speed of
the winch. If the winch is used for a considerable time with the
engine off the battery may be drained and too weak to restart the
engine
•Get to know your winch before you actually need to use it. We
recommend that you set up a few test runs to familiarize yourself
with rigging techniques, the sounds your winch makes under
various loads, the way the strap spools on the drum, etc.

6
•Inspect the strap and equipment before each use. A frayed or
damaged strap shall be replaced immediately. Use only
manufacturer’s identical replacement strap with the exact
specifications.
•Inspect the winch installation and bolts to ensure that all bolts are
tight before each operation.
•Store the remote control inside your vehicle in a place that it will not
be damaged.
•Any winch that appears to be damaged in any way, is found to be
worn, or operates abnormally SHALL BE REMOVED FROM
SERVICE UNTIL REPAIRED. It is recommended that the
necessary repairs be made by a manufacturer’s authorized repair
facility.
•Only attachments and/or adapters supplied by the manufacturer
shall be used.
WINCHING TECHNIQUES A-X
a. Take time to assess your situation and plan your pull.
b. Put on gloves to protect your hands.
c. Disengage the clutch to allow free-spooling and also save battery power.
d. Attach the hand saver hook to the clevis hook.
e. Pull out the strap to your desired anchor point using the hand saver hook.
f. Secure the clevis hook to the anchor point: Sling, chain or snatch block. Do not
attach the hook back onto the strap.
g. Engage the clutch.
h. Connect the remote control to the winch.
i. Start your engine to ensure power is being replenished to the battery.
j. Power in the strap guiding the strap under tension to draw up the slack in the strap.
Once the strap is under tension stand well clear. Never step over the strap.
k. Double check your anchors and make sure all connections are secure.
l. Clear the area. Make sure all spectators all well back and that no one is directly in
front or behind the vehicle or anchor point.
m. Begin winching. Be sure that the strap is winding evenly and tightly around the
drum. The vehicle that is being winched can be slowly driven to add assistance to the
winching process. Avoid shock loads; keep the strap under tension.

7
n. The vehicle to be winched should be placed in neutral and the emergency brake
released. Only release the brake pedal when under full tension. Avoid shock loads to
the winch. This can damage the winch, rope and vehicle.
o. The winch is meant for intermittent use. Under full load with a single line rig do not
power in for more than a minute without letting the motor cool down for a few minutes
and then resume the winching operation.
p. The winching operation is complete once the vehicle is on stable ground and is able
to drive under its own power.
q. Secure the vehicle. Be sure to set the brakes and place the vehicle in park.
r. Release the tension on the strap. The winch is not meant to hold the vehicle for long
periods of time.
s. Disconnect the strap from the anchor.
t. Rewind the strap. Make sure that any strap already on the drum has spooled tightly
and neatly. If not, draw out the strap and re-spool from the point where the strap is
tight.
u. Keep your hands clear of the winch drum and fairlead as the strap is being drawn
in.
v. Secure the hook and hook strap.
w. Disconnect the remote control and store in a clean, dry place.
x. Clean and inspect connections and mounting hardware for next winching operation.
MAINTENANCE
1. Periodically check the tightness of mounting bolts and electrical connections.
Remove all dirt or corrosion and always keep clean.
2. Do not attempt to disassemble the gear box. Repairs should be done by the
manufacturer or an authorized repair center.
3. The gear box has been lubricated using a high temperature lithium grease and is
sealed at the factory. No internal lubrication is required.

8
REPLACING THE STRAP
1. If the strap has become worn or is beginning to show signs of strands breaking, it
must be replaced before being used again. To do this, remove the defective
strap by free spooling. Remove the screw M4x6 (Part# NWB300015) on the
drum and take out the winch drum; disassemble the pin (Part#
NWB300014)release the strap.
2. Replace the new strap and assemble the winch.
3. Ensure that the strap is re-spooling in the under wind position.
4.
WARNING - Only replace the strap with the identical replacement part
recommended by the manufacturer.

9
TROUBLE SHOOTING
SYMPTOM
POSSIBLE CAUSE
SUGGESTED ACTION
Motor does not
turn on
-Switch Assembly not
connected properly
-Loose battery cable
connections
-Defective Switch
Assembly
-Defective motor
-Water has entered motor
-Insert Switch Assembly all the way into
the connector.
-Tighten nuts on all cable connections.
-Replace Switch Assembly.
-Check for voltage at armature port with
Switch pressed. If voltage is present,
replace motor.
-Allow to drain and dry. Run in short
bursts without load until completely dry.
Motor runs but
cable drum does
not turn
-Clutch not engaged
-Turn clutch to the “In” position. If problem
persists, a qualified technician needs to
check and repair.
Motor runs slowly
or without normal
power
-Insufficient current or
voltage
-Battery weak, recharge. Run winch with
vehicle motor running.
-Loose or corroded battery cable
connections. Clean, tighten, or replace.
Motor overheating
-Winch running time too
long
-Allow winch to cool down periodically.
Motor runs in one
direction only
-Defective Switch
Assembly
-Loose or corroded battery cable or motor
cable connections. Clean and tighten.
-Repair or replace switch assembly.

10
WINCH ASSEMBLY DRAWING
12
Fixing Panel
(1.96')
Red Battery +
(5.9')
Black Motor - Black Battery -
IN OUT
Red Motor +

11
WINCH PARTS LIST (SP3000)
No.
Part #
Qty
Description
Remark
1
SP300001
2
Terminal Protector
2
SP300100
1
Motor Assembly
3
SP300200
1
Gear-Box Assembly
4
SP300002
1
Support Ring（Ⅰ）
5
SP300300
1
Planetary Gear Assembly
6
SP300400
1
Output Gear Ring Assembly
7
SP300003
1
Drum Holder Plate
8
SP300004
4
Spring Washerø4
9
SP300005
4
Phillip Screw M4 x 12
10
SP300006
1
Bush（Ⅰ）
11
SP300007
1
Drum
12
SP300008
1
Bush
13
SP300009
1
Tie Bar
14
SP300010
1
Base Plate
15
SP300011
1
Screw M8 x 20
16
SP300012
1
Nylon Strap
17
SP300500
2
Mounting Screw Assembly (M8 x 35)
18
SP300013
2
Screw M6 x 16
19
SP300014
1
Pin
20
SP300015
1
Screw M4 x 6
21
SP300600
1
ATV Handlebar Switch
22
SP300700
1
ATV Control Box Fixing Panel
23
SP300800
4
ATV Control Box Mountings
24
SP300900
1
A Type Control Box

12
SPECIFICATION
Maximum line pulls: 600 lbs (2.67 kN) ;
Gear reduction ratio: 153:1;
Motor: Permanent magnet motor; 0.7hp/540 W (600 lbs)
0.4 hp / 300 W (DC 12V)（Max Output Power）;
Overall dimensions: 10.6" (L) x 4.0" (W) x 5.0" (H) ;
268(L) mm X 102 (W) mm X 127 (H) mm ;
Drum size: Ø 0.79" (D) x 1.7" (L) ;
Ø 20 (D) mm x 42 (L) mm ;
Nylon strip: 1.6" (W) x 2.4' (L) ;
40 mm (W) x 0.73 m (L) ;
Weight (winch): 13.2 lbs ( 6.0kgs ) ;
Total Weight: 16.1 lbs ( 7.3 kgs ) ;
Line speed and motor current (First layer)
Line pull
Line speed
ft/min (m/min)
Motor current
Amps (Max)
lbs (kN)
12V DC
12V DC
0
14（4.5）
10
250（1.1）
11.5（3.5）
30
600（2.67）
10.5（3.2）
45
Using in Special case:
250 lbs with 8 inches high Lifting: lifting time 5 second while ampere is 30A.
Minimum 5000 times cycles without failure.
Lifting 600 lbs with 8 inches high, lifting time 7 second while ampere is 45A.
Minimum 1500 times cycles without failure.
Start / stop of operating ampere 65 A maximum.