Extreme Max 5600.3060 Operator's manual

Installing your Universal
Contactor / Relay and Mini Rocker
Switch Kit (5600.3060)

YELLOW COVER (BLACK LINE)
BLUE COVER (RED LINE)
BLACK
RED

Installing the Rocker Switch:
1. Assemble and position the switch
mount assembly on handle bars in a
convenient location.
2. Bolt Rocker Switch to mount and
adjust for convenient location
3. Route wire from Rocker Switch down
handle bars. Turn handle bars fully
right and left to ensure sufficient
clearance.
4. Carefully route wire to solenoid and
screw in to matching connector.
5. Make sure that wires are not pulled taut against any surfaces that could
damage them or be in contact with the exhaust system. Use cable ties to
secure wires. Tie off any excess wire.
Wiring to Solenoid:
The Bear Claw™ Electronics Package comes pre-wired. Only connections
to the winch motor and to the battery are necessary.
Caution: Tighten Nuts on Terminal Studs to 35-40 in-lbs
(3-4 Nm) torque. Do not over-tighten.
Final Check on Connections to Winch and Battery
These connections are color coded
1. Connect the yellow coded power cable to the corresponding terminal on
the winch (position cable and tighten)
2. Connect the green coded power cable to the corresponding terminal on
the winch (position cable and tighten)
3. Connect red coded power cable to positive battery terminal (position cable
and tighten)
4. Connect black coded power cable to – negative terminal on battery
(position cable and tighten)
Make sure to recheck cable routing to make sure they do not interfere with
any moving parts or are in contact with any thing that gets hot.
Use the supplied cable ties to secure power cables to maintain proper
placement.
Finish Installation:
1. Confirm that the winch clutch is disengaged.
2. Connect negative (-) battery cable to vehicle battery. Use Black Battery
Lead to connect winch and negative (-) vehicle battery terminal.
3. Spool out a few feet of cable by hand. Engage winch clutch.
4. Push Rocker Switch to “OUT” winch should begin to spool cable out.
5. Push Rocker Switch to “IN” Winch should begin to reel cable in.

Condition Possible
Cause Correction
Motor runs
extremely hot
Prolonged
Operation
Cooling-off periods are essential to
prevent over-heating.
Motor runs
with insufficient
power or low line
speed
Low Battery
Bad Connection
Insufficient
Charging System
Test for faulty battery
Check battery cable for corrosion, clean
and grease.
Replace with larger capacity charging
system.
Motor runs but
drum does not
turn
Clutch not
engaged
If clutch is engaged while symptoms
exist, it will be necessary to disassemble
winch to determine the cause and
appropriate repairs.
Motor will not
operate
Defective or
stuck solenoid
Defective Rocker
Switch
Defective Motor
Loose
Connections
Jar solenoid assembly to free contacts.
Check solenoid by applying 12 volts to
coil terminal. (It should make an audible
click when energized)
Replace Rocker Switch
If solenoids operate, check for voltage at
armature post; replace motor.
Check all electrical leads from the battery
to the motor.
Water Damage
Submerged in
water or high
pressure car
wash
Drain and dry thoroughly. Run motor
without a load to drain and dry windings.
Winch runs
in opposite
direction of
transmitter
buttons
Motor leads
crossed Reverse electrical connections to motor.
Trouble Shooting
project #