Ironman4x4 Monster Winch User manual

USER GUIDE
IMPORTANT: Please read all safety warnings and precautions before installing
and using the Ironman 4x4 Monster Winch. If you have any questions please
contact our customer service department listed on the back of the user guide.
Sales & service world wide
www.ironman4x4.com

SAFETY
CLOTHING
•฀Don’t฀wear฀loose฀tting฀clothing฀or฀jewellery฀as฀they฀can฀get฀caught฀in฀moving฀parts•฀฀Always฀wear฀leather฀gloves฀when฀handling฀the฀winch฀cable.฀Do฀not฀handle฀with฀bare฀hands฀as฀broken฀strands฀can฀cause฀injury.•฀Non-skid฀footwear฀should฀be฀worn.฀Open฀toed฀footwear฀is฀not฀recommended.•฀Protective฀hair฀covering฀should฀be฀worn฀to฀protect฀long฀hair.KEEP A SAFE DISTANCE
•฀฀Always฀keep฀hands฀clear฀of฀rope฀or฀cable,฀hook฀loop,฀hook฀and฀fairlead฀opening฀during฀installation,฀operation฀or฀when฀spooling฀in฀or฀out.•฀Always฀use฀extreme฀caution฀when฀handling฀hook,฀rope฀or฀cable฀during฀spooling฀operation.•฀฀Always฀use฀hook฀strap฀supplied฀whenever฀spooling฀wire฀rope฀in฀or฀out฀to฀avoid฀injury฀to
hands฀or฀ngers.•฀฀Ensure฀that฀all฀persons฀stand฀well฀clear฀of฀winch฀cable฀and฀load฀during฀winch฀operation.฀
1.5 times the cable length is recommended as a safe distance. If a cable pulls loose or
breaks฀under฀load฀it฀can฀lash฀back฀and฀cause฀serious฀injury฀or฀death.•฀฀Always฀use฀your฀Ironman฀4x4฀winch฀blanket฀supplied฀with฀winch฀to฀prevent฀cable฀lashing฀back in the event of it pulling loose or breaking under load.
•฀Never฀step฀over฀or฀stand฀on฀cable.•฀All฀onlookers฀should฀be฀kept฀well฀away฀from฀work฀area.OPERATION
•฀Never฀allow฀persons฀unfamiliar฀with฀this฀product฀to฀operate฀it.•฀฀Your฀winch฀is฀not฀designed฀or฀intended฀to฀be฀used฀for฀over฀head฀lifting฀or฀hoisting฀operations.•฀Never฀use฀your฀winch฀for฀lifting฀or฀moving฀people.•฀Never฀use฀your฀winch฀while฀under฀the฀inuence฀of฀alcohol฀or฀drugs•฀Never฀allow฀your฀winch฀to฀be฀operated฀by฀any฀person฀under฀the฀age฀of฀16.CONDITION
•฀฀Inspect฀wire฀cable฀or฀rope฀and฀winch฀components฀frequently฀for฀damage.฀A฀attened,
frayed or kinked cable could fail under load and needs to be replaced immediately.
•฀Periodically฀check฀winch฀mounting฀bolts฀to฀ensure฀they฀are฀tight.Safety
User Guide
4Getting Started
6Pre Tensioning
7฀Spooling฀Your฀Cable฀
8Winching Tips
9฀Finding฀A฀Suitable฀Anchor฀Point฀
12 Winching Techniques
Fitting Your Winch
16 Installation Steps
20฀Hook฀AssemblyMaintenance
21฀Maintenance฀&฀CleaningTech Specifications
Gettin’ The Right Gear
Winch฀AccessoriesTroubleshooting
Warranty
WARNING: For personal safety and the safety of others please read and fully
understand these safety instructions before operating your winch. Failure to
do฀so฀could฀cause฀personal฀injury฀or฀damage฀to฀equipment.฀After฀installing฀the฀winch,฀practise฀using฀your฀winch฀before฀the฀need฀arises.3
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PLAYING IT SAFE
CONTENTS PLAYING IT SAFE CONTENTS
3

USER GUIDE
GETTING STARTED
GETTING STARTED
Thank you for purchasing your Ironman 4x4 recovery winch.
Your฀winch฀will฀give฀you฀many฀years฀of฀reliable฀service฀if฀you฀follow฀the฀instructions฀covered฀in฀this hand book. Before using your winch it is important to familiarise yourself with your winch
and฀how฀it฀works,฀and฀pay฀particular฀attention฀to฀the฀safety฀information.•฀฀Your฀Ironman฀4x4฀vehicle฀recovery฀winch฀is฀designed฀for฀vehicle฀recovery,฀and฀is฀not฀designed฀for฀lifting,฀hoisting฀or฀commercial฀applications.•฀฀Your฀winch฀needs฀to฀be฀mounted฀securely฀to฀a฀winch฀bar฀or฀winch฀mount฀designed฀and฀tested for your vehicle.
•฀Your฀winch฀needs฀to฀be฀connected฀to฀a฀battery฀of฀at฀least฀650cca.The winch has a clutch handle mounted on the gearbox that is used to engage and disengage
the cable drum from the gearbox. The handle can only be moved when there is no load on the
cable. Because the clutch gear has straight cut teeth sometimes the drum might need to be
rotated slightly to align the teeth on the gears before the handle can be moved.
Disengage
With the clutch handle in the disengage position the cable drum will free spool enabling the
cable to be pulled out by hand.
Engage
With the clutch handle in the engage position the cable drum is connected to the gearbox. This
allows the cable to be powered in and out using the winch motor.
NOTE: When pulling the cable out it is preferable to free spool the cable rather than
powering the cable as powering the cable out can build up heat in the internal brake
of the winch unnecessarily.
Your winch can either be operated using the plug in hand controller or the cordless
function. A button is located on the side of the hand controller to switch operation
between cordless and plug in function.
Cordless
For฀cordless฀operation,฀the฀wireless฀activator฀must฀be
connected to the socket on top of the control box.
NOTE:฀฀Wireless฀Activator฀must฀always฀be
removed from control box when winch is not
being used to prevent unintentional activation
of฀winch.฀If฀this฀occurs,฀it฀will฀not฀be฀covered
by warranty.
With the cord unplugged from the controller and the
(wireless฀LED)฀illuminated฀on฀the฀hand฀controller฀the฀winch฀can฀be฀powered฀in฀and฀out฀using฀the฀direction switch.
Plug in
To฀use฀the฀plug฀in฀option,฀connect฀the฀cord฀to฀the฀hand฀controller฀and฀plug฀the฀controller฀into฀the฀socket฀on฀top฀of฀the฀control฀box.฀Push฀the฀button฀on฀the฀handle฀to฀illuminate฀the฀(wired฀LED).฀฀The winch can now be powered in and out using the direction switch.
Brake
Your฀winch฀has฀a฀one฀directional฀cam฀lock฀brake฀inside฀the฀cable฀drum.฀The฀purpose฀of฀the฀brake is to prevent the vehicle rolling backwards when winching up a hill and the power is
released from the motor. For this reason the cable can only be wound onto the drum in one
direction.฀If฀the฀cable฀is฀wound฀onto฀the฀drum฀in฀the฀wrong฀direction฀the฀brake฀will฀not฀work,
and will engage whilst winching the cable in which will over heat the brake and possibly the
motor. This will not be covered by warranty.
Before winching please refer to the safety section on Page 4 of this hand book.
5

USER GUIDE
Spooling Out
The quickest and easiest way spool the cable out from the drum is to free spool it with the
clutch handle in the disengaged position. To do this power the winch out slightly to take the
tension฀off฀the฀cable฀and฀rotate฀the฀clutch฀handle฀to฀the฀disengage฀position,฀and฀pull฀the฀cable฀out to the chosen anchor point. The other option is to power the cable out which is a much
slower฀process฀and฀will฀heat฀up฀the฀brake฀in฀the฀cable฀drum,฀this฀is฀not฀recommended.฀฀฀฀Note:฀Always฀leave฀at฀least฀5฀wraps฀of฀cable฀on฀the฀drum.฀Although฀the฀end฀of฀the฀cable฀is฀attached฀to฀the฀drum฀with฀a฀lug,฀it฀is฀not฀designed฀to฀hold฀any฀load฀and฀will฀tear off the end of the cable or may damage the cable lug if less than 5 wraps remain
on the drum. If this happens it will not be covered by warranty.
Spooling in with no load
Before spooling cable please refer to the safety section of this manual.
Clutch฀handle฀will฀need฀to฀be฀in฀the฀engaged฀position฀for฀this฀process.฀When spooling the cable onto the winch for storage it is important that it is wound tightly and
evenly฀onto฀the฀drum.฀To฀do฀this฀refer฀to฀the฀cable฀pre-tensioning฀section฀on฀Page฀6,฀or฀have฀an฀assistant฀hold฀as฀much฀tension฀as฀possible฀onto฀the฀hook,฀using฀the฀hook฀strap,฀and฀walk฀towards the winch while you operate the hand control and guide the cable evenly onto the
drum.฀The฀hook฀can฀be฀pulled฀rmly฀against฀the฀fairlead฀or฀anchored฀to฀a฀recovery฀hook฀on฀the฀vehicle.
฀฀฀Note:฀Do฀not฀over฀tension฀cable฀or฀damage฀may฀occur฀to฀fairlead,฀winch฀bar฀or฀recovery฀hook฀on฀vehicle.฀Care฀must฀be฀taken฀not฀to฀get฀hands฀caught฀in฀cable,฀fairlead฀or฀any฀other฀moving฀parts฀of฀winch.฀Always฀use฀the฀hook฀strap฀and฀gloves฀when฀re-spooling฀the฀cable฀never฀use฀bare฀hands.฀Always฀make฀sure฀that฀cable฀for฀hand controller is kept well away from cable or any other moving parts to prevent it
from becoming tangled.
Pre-Tensioning
It฀is฀very฀important฀to฀pre฀tension฀the฀cable฀before฀the฀rst฀time฀the฀winch฀is฀used.฀Failure฀to฀do฀this will dramatically shorten the life of the cable and will not be covered by warranty.
To฀do฀this฀the฀following฀procedure฀must฀be฀followed:฀1. Find a fairly level or slightly inclined surface that has enough room to spool the cable off the
drum down to the last 5 wraps of the drum.
2. Turn the clutch handle on the winch gearbox to the disengage position and pull the cable out
to฀the฀last฀5฀wraps฀on฀the฀drum.฀Never฀unwind฀the฀cable฀to฀less฀than฀5฀wraps฀on฀the฀drum.฀Although฀the฀end฀of฀the฀cable฀is฀attached฀to฀the฀drum฀with฀a฀lug,฀it฀is฀not฀designed฀to฀hold฀any load and will tear off the end of the cable or may damage the cable lug if less than 5
wraps remain on the drum. If this happens it will not be covered by warranty.
3. Turn the clutch handle on the winch gearbox to the engaged position.
4. Securely attach the hook end of the cable to a suitable anchor point and slowly back the
vehicle away until the slack is taken out of the cable.
To pretension the cable properly it will need to be spooled back onto the drum evenly with a
load฀of฀at฀least฀450฀kg฀(1000฀lbs).฀This฀load฀can฀be฀applied฀by฀lightly฀engaging฀the฀hand฀brake฀or฀having฀a฀second฀person฀lightly฀applying฀the฀foot฀brake฀while฀re-spooling฀the฀cable.5.฀฀Start฀the฀engine฀of฀the฀vehicle.฀Using฀your฀hand฀controller,฀start฀to฀re-spool฀the฀cable฀back฀onto the drum so that it spools evenly with no gaps between each wind. If gaps occur
unwind฀the฀cable฀slightly฀and฀then฀re-spool฀it.฀Note:฀Extreme฀care฀must฀be฀taken฀not฀to฀get฀your hand caught in the fairlead or any moving parts of the winch.
6.฀฀Once฀the฀cable฀has฀spooled฀to฀within฀2฀metres฀of฀the฀hook,฀stop฀winching฀and฀apply฀the฀hand฀brake฀of฀the฀vehicle฀rmly.฀Reverse฀the฀winch฀slightly฀to฀release฀the฀load฀from฀the฀cable.
7. Unhook the cable from its anchor. While holding onto the hook with the supplied hook strap
spool the remainder of the cable in. The hook can attached to a recovery point on the vehicle
or carefully winched in against the fairlead taking care not to over tension it or this could
cause damage to the vehicle or bull bar.
Always฀use฀supplied฀hook฀strap฀when฀spooling฀cable฀to฀prevent฀hands฀from฀getting฀caught฀in฀fairlead or other moving parts.
During฀heavy฀winching฀heat฀will฀build฀up฀in฀the฀electric฀motor.฀Periodically฀stop฀winching฀and฀touch฀the฀motor฀with฀your฀bare฀hand,฀if฀it฀is฀uncomfortably฀hot฀to฀touch฀stop฀winching฀for฀long฀enough฀for฀it฀to฀cool฀down.฀Failure฀to฀do฀this฀could฀cause฀damage฀the฀motor,฀Which฀will฀not฀be฀covered by warranty.
WARNING:฀Never฀operate฀winch฀with฀less฀than฀5฀wraps฀on฀the฀drum.฀Cable฀could฀come฀adrift฀from฀the฀drum฀as฀the฀attaching฀lug฀is฀not฀designed to hold any load
7

USER GUIDE
Winching Tips
IMPORTANT: Before winching under load please refer to the safety section of
this manual.
It is very important to select an anchor point strong enough to hold while winching. If using
a฀tree,฀it฀is฀important฀to฀use฀a฀tree฀trunk฀protector฀to฀prevent฀damage฀to฀the฀tree฀and฀also฀to฀prevent฀kinking฀the฀cable,฀and฀always฀make฀sure฀that฀the฀anchor฀point฀is฀as฀low฀as฀possible.฀Ideally choose an anchor point that is as straight as possible in the direction that the vehicle
needs to travel. If winching on an angle it is important to make sure that the cable spools onto
the฀drum฀evenly฀and฀does฀not฀bunch฀up฀at฀one฀end฀of฀the฀drum,฀if฀this฀happens฀the฀cable฀can฀run฀out฀of฀room฀and฀break฀the฀tie฀rods฀that฀hold฀the฀winch฀together,฀this฀will฀render฀the฀winch฀inoperable. This will not be covered by warranty.
If฀a฀natural฀anchor฀point฀such฀as฀a฀tree฀or฀tree฀stump฀can’t฀be฀found฀then฀a฀sand฀anchor,฀or฀similar can be used. In some circumstances a spare wheel or log can be buried deeply in the
ground฀and฀used฀as฀an฀anchor฀point,฀but฀extreme฀caution฀must฀be฀used.฀฀฀Never฀hook฀the฀wire฀rope฀back฀onto฀itself.฀This฀will฀damage฀the฀wire฀rope.฀Always฀use฀a฀choker฀chain,฀a฀wire฀choker฀or฀tree฀trunk฀protector฀on฀the฀anchor.The further the cable is spooled off the drum the more pulling power the winch will have.
Always฀leave฀it฀least฀5฀wraps฀if฀cable฀on฀the฀drum.฀Never฀exceed฀the฀rated฀pulling฀capacity฀of฀the฀winch,฀if฀the฀winch฀will฀not฀recover฀the฀vehicle฀using฀a฀single฀line฀pull฀then฀a฀snatch฀block฀will be required to perform a double or even triple line pull. This is covered on Page 12 of this
manual.
Before winching always ensure your winch is mounted securely and check the condition of
the฀winch฀rope฀/฀cable฀and฀hook.฀If฀your฀rope฀/฀cable฀is฀damaged,฀kinked฀or฀frayed฀replace฀it฀immediately.
Finding A Suitable Anchor Point
When choosing an anchor point it is crucial that it will be strong enough to hold while winching.
Always฀try฀to฀winch฀in฀a฀straight฀line฀away฀from฀the฀winch฀to฀prevent฀the฀cable฀bunching฀up฀at฀one end of the drum causing damage to the winch.
Always฀connect฀the฀winch฀cable฀to฀the฀anchor฀point฀as฀low฀to฀the฀ground฀as฀possible.Never฀hook฀the฀cable฀back฀onto฀its฀self฀around฀an฀anchor฀point,฀as฀this฀will฀kink฀the฀cable.Always฀attach฀the฀winch฀cable฀to฀the฀anchor฀point฀using฀the฀appropriate฀rigging฀equipment,฀such฀as฀a฀tree฀trunk฀protector,฀choker฀chain฀or฀cable฀connected฀to฀a฀bow฀shackle฀rated฀for฀winching.
If anchoring to another vehicle make sure that the cable is only attached to a rated recovery
point. If unsure refer to the owners manual of your vehicle.
An฀anchor฀point฀as฀far฀away฀as฀practical฀is฀preferable฀because฀the฀winches฀pulling฀power฀in฀increased฀the฀less฀cable฀there฀is฀on฀the฀drum.฀Always฀make฀sure฀that฀there฀is฀at฀least฀5฀wraps฀of cable left on the drum.
If no suitable anchor point can be found, other options can be used with extreme
caution. The following options are shown below:
Your฀spare฀wheel฀and฀tyre฀can฀be฀used฀as฀an฀anchoring device by burying it deeply into the ground
and securing to a chain or winch extension strap.
A฀sturdy฀log฀can฀be฀used฀as฀an฀anchoring฀device฀by฀burying it deeply into the ground and securing to a
chain or winch extension strap.
SAND ANCHOR
SPARE WHEEL
LOG
9

USER GUIDE
Winching - Single Line Pull
IMPORTANT: Before winching please refer to the safety section of this manual.
Using฀your฀hand฀controller,฀un-spool฀cable฀slightly฀to฀release฀the฀tension฀on฀the฀cable฀and฀turn
the clutch handle to the disengage position.
Pull฀the฀cable฀out฀to฀the฀chosen฀anchor฀point฀and฀attach฀it฀using฀a฀tree฀trunk฀protector,฀choker฀chain฀or฀similar.฀Never฀hook฀the฀cable฀back฀onto฀itself฀as฀this฀will฀kink฀the฀cable.฀฀Always฀attach฀the cable as low to the ground as possible. The further the cable is spooled of the drum the
more฀pulling฀power฀the฀winch฀will฀have,฀but฀always฀leave฀at฀least฀5฀wraps฀on฀the฀drum.฀Always฀try to choose an anchor point as straight as possible in the direction the vehicle needs to travel.
Re-engage฀the฀clutch฀handle฀on฀the฀winch.฀Using฀your฀hand฀controller฀spool฀the฀cable฀in฀slightly฀to฀take฀up฀the฀slack.฀Drape฀the฀winch฀blanket฀supplied฀with฀your฀winch฀over฀the฀cable฀and฀attach the hook and loop tabs.
NOTE: This diagram shows wire cable. For synthetic rope damper blanket should
be draped over hook end of the rope.
Always฀make฀sure฀when฀winching฀under฀load฀that฀the฀winch฀dampening฀blanket฀supplied฀with฀your฀winch฀is฀draped฀over฀your฀cable฀or฀rope.฀For฀wire฀cable,฀the฀blanket฀should฀be฀draped฀roughly two thirds of the way towards the hook. For synthetic rope the blanket should be at the
hook end of the cable.
Synthetic Rope Wire Cable If฀multiple฀blankets฀are฀required฀when฀doing฀a฀double฀or฀triple฀line฀pull,฀a฀rag,฀jacket฀or฀solid฀branch can be used as a cable dampener.
Making sure that all onlookers are a safe distance away you are now ready to start recovering
your vehicle. When recovering the vehicle someone should always be in the drivers seat.
It is important that all people around you know that you are winching and that clear
communication is kept with the person in the vehicle.
Start the vehicles engine and release the vehicles hand brake. Begin winching using the hand
controller. The vehicle can be driven slowly to assists the winch. If the winch stalls release the
switch on the hand controller as this will over heat and burn the motor out. This will not be
covered by warranty. In this instance it might be necessary to perform a double line pull using a
snatch block.
While฀winching,฀stop฀periodically฀to฀touch฀the฀motor฀with฀your฀bare฀hand.฀If฀the฀motor฀is฀uncomfortably hot to touch you will need to wait for it to cool down before you continue
winching.฀Also฀check฀that฀the฀cable฀is฀spooling฀on฀evenly฀and฀not฀bunching฀up฀at฀one฀end฀of฀the฀drum.฀If฀this฀happens฀the฀cable฀can฀run฀out฀of฀room฀and฀break฀the฀winch฀tie-rods.If the cable is not evenly and tightly wound onto the drum the outer wraps of the cable can be
drawn฀into฀the฀inner฀wraps฀binding฀and฀damaging฀the฀cable.฀If฀this฀happens,฀engage฀the฀hand฀brake฀on฀the฀vehicle฀and฀spool฀the฀cable฀off฀the฀drum฀slightly฀to฀a฀point฀where฀it฀can฀be฀re-spooled neatly until the cable has tension and winching can recommence.
As฀you฀winch฀in,฀avoid฀shock฀loading฀the฀cable฀by฀switching฀the฀controller฀intermittently.฀Shock฀loads can momentarily far exceed the load rating of the winch and the cable.
Once฀the฀vehicle฀has฀been฀winched฀clear฀of฀the฀obstacle,฀engage฀the฀hand฀brake฀and฀spool฀the฀cable฀out฀slightly฀to฀release฀the฀load.฀Disconnect฀the฀cable฀from฀the฀anchor฀point.With฀an฀assistant฀holding฀as฀much฀tension฀as฀possible฀onto฀the฀hook,฀using฀the฀hook฀strap฀provided,฀re-spool฀the฀cable฀neatly฀onto฀the฀drum.Winching is now complete.
TREE TRUNK
PROTECTOR
RATED
D-SHACKLE
SINGLE LINE PULL
ANCHOR
POINT
WINCH DAMPER
BLANKET
11

USER GUIDE
Winching Techniques
Different฀winching฀situations฀require฀different฀winching฀techniques.฀This฀section฀covers฀various฀ways improving the versatility of your winch.
Double & Triple Line Pull
The pulling power of your winch increases with less winds of cable on the drum. If the only
anchor point available is too close to your winch you can loop the cable through a snatch block
and attach the hook end of your cable back to the rated recovery hook on your vehicle. This
uses more cable off the drum and the snatch block also increases the mechanical advantage of
the฀winch,฀and฀therefore฀decreases฀the฀effort฀required.Two฀snatch฀blocks฀can฀be฀used฀to฀further฀reduce฀the฀effort฀required฀by฀your฀winch,฀this฀is฀called฀a triple line pull.
Using A Snatch Block
In certain instances extra pulling power will be required to recover a vehicle. If your winch stalls
under load it can quickly build up excessive heat in the motor which can cause serious damage.
Using a snatch block can halve the effort required by your winch by increasing its mechanical
advantage.฀A฀snatch฀block฀can฀also฀be฀used฀to฀change฀the฀pulling฀direction.฀Winching฀should฀always฀be฀done฀in฀a฀straight฀line฀from฀the฀winch฀to฀the฀object฀being฀winched,฀this฀prevents฀the฀winch from being damaged due to the cable being bunched up at one end of the cable drum.
DOUBLE LINE PULL
ANCHOR
POINT
TREE TRUNK
PROTECTOR
SNATCH
BLOCK
RATED
D-SHACKLE
WINCH DAMPER
BLANKET
TRIPLE LINE PULL
ANCHOR
POINT
ANCHOR
POINT
SNATCH
BLOCKS
TREE TRUNK
PROTECTORS
RATED
D-SHACKLES
WINCH DAMPER
BLANKET
CHANGING DIRECTION
RATED
D-SHACKLE
SNATCH
BLOCK
RECOVERY
POINT
ANCHOR
POINT
WINCH DAMPER
BLANKET
NOTE: This diagram shows wire cable.
For synthetic rope damper blanket should
be draped over hook end of the rope.
13

on your next
adventure
unleash the
Monster

INSTALLATION
IMPORTANT:฀฀Before฀winch฀is฀installed฀to฀winch฀cradle,฀the฀clutch฀handle฀might฀need
to฀be฀rotated฀to฀a฀more฀convenient฀position฀for฀access฀through฀bull฀bar.฀To฀do฀this,฀refer to the following steps.
1. Stand winch vertically on motor with gearbox
facing upwards.
฀฀NOTE:฀If฀shaft฀comes฀out฀of฀cable฀drum฀remove it from the gearbox and place it back
into the drum making sure it engages with
the brake. ฀฀NOTE:฀Also฀make฀sure฀that฀the฀drum฀support฀bush remains in the end of the drum support
housing with the locating tang in the correct
position.
4.฀฀Undo฀and฀remove฀10฀Allen฀head฀bolts฀that฀hold the gearbox housing to the drum support
housing and rotate the drum support housing
to the desired location. Make sure the
gearbox gasket does not tear.
5.฀Re-install฀10฀bolts฀and฀tighten฀rmly.฀NOTE:฀Take฀care฀not฀to฀over-tighten.2.฀฀Undo฀and฀remove฀2฀chrome฀Allen฀head฀bolts฀which hold the gearbox to the tie rods.
3. Lift gearbox off winch.
FITTING YOUR
MONSTER WINCH
MONSTER WINCH
FITTING YOUR
6.฀฀Ret฀gearbox฀to฀winch,฀ret฀and฀tighten฀Allen฀head bolts into tie rods.
17

INSTALLATION
11.฀฀Connect฀three฀colour฀coded฀cables฀to฀the
corresponding poles on winch motor. 12.฀฀Connect฀the฀thin฀black฀earth฀wire฀and฀negative battery cable to the earth connection
on the opposite side of winch motor.
WARNING: Failure to do this step will void
ALL warranty.
13.฀฀Run฀the฀positive฀and฀negative฀battery฀cables฀into the engine bay taking care to secure
cables away from any sharp or moving
objects.฀Connect฀to฀main฀battery.฀฀฀Connect฀red฀cable฀to฀positive฀terminal฀on฀main฀battery.฀Connect฀black฀cable฀to฀negative฀terminal on main battery.
14. Find a convenient location in the engine bay
as high as possible to mount remote motor
breather
฀฀Connect฀hose฀to฀barb฀tting฀on฀side฀of฀winch฀motor.฀Cable฀tie฀hose฀away฀from฀sharp฀or฀moving฀objects.10.฀฀Place฀control฀box฀on฀top฀of฀centre฀pan฀of฀bull bar as shown. Mark position of the four
mounting bolts.
฀฀Drill฀four฀holes฀to฀6.5mm.฀Rust฀proof฀and฀฀de burr and attach control box to bar.
7. Bolt winch to cradle. For most applications
the gearbox will go to the left hand side of
vehicle and cable spooling from bottom of
the cable drum using bolts and washers
provided.
8. Bolt roller / hawse fairlead to recess in front
of฀bull฀bar฀using฀bolts,฀washers฀and฀nuts฀provided.
19

MAINTENANCE
Your Ironman 4x4 Monster winch will require very little maintenance as long as it is
cared for in the following manner.
1.฀฀Although฀every฀precaution฀is฀taken฀in฀the฀design฀of฀your฀winch฀to฀prevent฀water฀or฀moisture฀from entering its internal workings it is unavoidable for some moisture to accumulate inside
due฀to฀weather฀conditions,฀condensation,฀steam฀cleaning,฀river฀crossings฀etc.To prevent moisture from causing damage it is recommended that the winch be used on a
regular basis to heat up the inside of the winch and dissipate any condensation. This will
also ensure that the lubricant inside the winch covers all of the internal surfaces that could
be potentially be effected by corrosion.
฀฀This฀process฀is฀as฀simple฀as฀(once฀a฀month฀)฀or฀after฀winch฀has฀been฀subjected฀to฀very฀wet฀conditions฀power฀the฀winch฀out฀about฀15m,฀and฀free฀spool฀for฀another฀5m.฀Then฀with฀the฀vehicle฀on฀a฀slight฀incline฀or฀with฀the฀parking฀brake฀slightly฀engaged,฀power฀the฀cable฀back฀neatly
on฀to฀the฀drum.฀This฀pre-tensioning฀will฀also฀prolong฀the฀life฀of฀the฀cable.This will also ensure that the winch is in good working order if it is required for vehicle
recovery.
2. The condition of the wire cable or synthetic rope should be checked on a regular basis or
before and after each winching operation. If damage is present such as kinks or fraying it
should฀be฀replaced฀with฀another฀rope฀or฀cable฀rated฀and฀specied฀for฀your฀winch.3.฀฀No฀lubrication฀should฀normally฀be฀required฀for฀the฀life฀of฀your฀winch,฀but฀if฀your฀winch฀has฀been submerged for a prolonged period of time and you suspect it has induced water it can
be serviced by your nearest Ironman 4x4 dealer.
4.฀฀Electrical฀connections฀should฀be฀checked฀on฀a฀regular฀basis฀to฀ensure฀they฀are฀clean
and tight.
•฀฀Do฀not฀direct฀high฀pressure฀water฀(pressure฀washers,฀car฀washes,etc.)฀Directly฀between฀drum฀support฀and฀drum฀ange฀or฀clutch฀lever.•฀Use฀low฀pressure฀water฀and฀a฀soapy฀rag฀or฀sponge฀to฀clean฀the฀winch.•฀Avoid฀using฀chemicals฀that฀may฀damage฀or฀cause฀corrosion฀to฀the฀nish฀of฀the฀winch.•฀Thoroughly฀clean฀salt฀residue฀from฀the฀winch฀as฀soon฀as฀possible฀to฀minimise฀corrosion.
KEEPIN’ IT
MAINTAINING
CLEAN
YOUR WINCH
KEEPIN’ IT
MAINTAINING
CLEAN
YOUR WINCH
21
5. Hammer pin into posiion.
4. Place ferrel in position as shown.
a)฀Hook-Loopb)฀Pinc)฀Ferrel2.฀Thread฀hook-loop฀through฀cable฀eye.3.฀P฀lace฀hook฀and฀pin฀in฀position฀on฀hook-loop฀as shown.
ac
b

TECHNICAL SPECIFICATIONS
9500lb Monster Winch - Steel Cable
Power฀12VDCMotor฀5.5HP฀/฀4.1KW,฀Series฀WoundHand฀Control฀Wireless฀Remote฀-฀Range฀30.5m฀(100ft)
฀Lead฀Remote฀-฀3.6m฀(12ft)฀LeadGear Train 3 Stage Planetary
Gear฀Reduction฀Ratio฀265:1Brake฀Automatic฀Cam฀lock฀(In฀Drum)Cable฀28m฀of฀8.3mm฀Diameter
฀(94ft฀of฀3/8”฀Diameter)Battery฀650CCA฀-฀minimum฀for฀winchingWeight฀N.W.฀42kg฀(90lbs)9500lb Monster Winch - Synthetic Rope
Power฀12VDCMotor฀5.5HP฀/฀4.1KW,฀Series฀WoundHand฀Control฀Wireless฀Remote฀-฀Range฀30.5m฀(100ft)
฀Lead฀Remote฀-฀3.6m฀(12ft)฀LeadGear Train 3 Stage Planetary
Gear฀Reduction฀Ratio฀265:1Brake฀Automatic฀Cam฀lock฀(In฀Drum)Synthetic฀Rope฀28m฀of฀8mm฀DiameterBattery฀650CCA฀-฀minimum฀for฀winchingWeight฀N.W.฀28kg฀(62lbs)12000lb Monster Winch - Steel Cable
Power฀12VDCMotor฀6.4HP฀/฀4.5KW,฀Series฀WoundHand฀Control฀Wireless฀Remote฀-฀Range฀30.5m฀(100ft)
฀Lead฀Remote฀-฀3.6m฀(12ft)฀LeadGear Train 3 Stage Planetary
Gear฀Reduction฀Ratio฀265:1Brake฀Automatic฀Cam฀lock฀(In฀Drum)Cable฀28m฀of฀9.5mm฀Diameter
฀(94ft฀of฀3/8”฀Diameter)Battery฀650CCA฀-฀minimum฀for฀winchingWeight฀N.W.฀54kg฀(119lbs)OVERALL DIMENSIONS
562mm฀(L)฀x฀215mm฀(H)฀x฀156mm฀(W)OVERALL DIMENSIONS
562mm฀(L)฀x฀215mm฀(H)฀x฀156mm฀(W)OVERALL DIMENSIONS
562mm฀(L)฀x฀215mm฀(H)฀x฀156mm฀(W)OVERALL DIMENSIONS
562mm฀(L)฀x฀215mm฀(H)฀x฀156mm฀(W)MOUNTING BOLT PATTERN
254mm x 114.3mm
MOUNTING BOLT PATTERN
254mm x 114.3mm
MOUNTING BOLT PATTERN
254mm x 114.3mm
MOUNTING BOLT PATTERN
254mm x 114.3mm
12000lb Monster Winch - Synthetic Rope
Power฀12VDCMotor฀6.4HP฀/฀4.5KW,฀Series฀WoundHand฀Control฀Wireless฀Remote฀-฀Range฀30.5m฀(100ft)
฀Lead฀Remote฀-฀3.6m฀(12ft)฀LeadGear Train 3 Stage Planetary
Gear฀Reduction฀Ratio฀265:1Brake฀Automatic฀Cam฀lock฀(In฀Drum)Synthetic฀Rope฀28m฀of฀9mm฀DiameterBattery฀650CCA฀-฀minimum฀for฀winchingWeight฀N.W.฀29kg฀(64lbs)
23

WINCH ACCESSORIES
GETTIN’ THE
RIGHT GEAR
GETTIN’ THE
RIGHT GEAR
Winch Damper Blanket
When winching under load a dampening blanket should
always be used. It is draped over the cable when it is
under tension to dampen its inertia if it snaps or comes
adrift from its anchor point. This will prevent it from
whipping฀and฀potentially฀injuring฀people฀or฀damaging฀the฀car or equipment.
To compliment your Ironman 4x4 Monster Winch,
the following accessories can be purchased
separately from your nearest Ironman 4x4 Stockist.
Tree Trunk Protector
A฀tree฀trunk฀protector฀is฀essential฀if฀using฀a฀tree฀as฀an฀anchor point. This prevents ring barking the tree.
It can also be used for several other applications when
connecting your cable or rope to an anchor point.
Winch Extension Strap
A฀winch฀extension฀strap฀can฀be฀connected฀to฀the฀hook฀end฀of the winch cable or rope to extend its length if a suitable
anchor฀point฀can’t฀be฀reached.Snatch Block
A฀snatch฀block฀is฀a฀valuable฀addition฀to฀your฀vehicle฀recovery winch. It allows you to maximise the pulling
power of your winch and allows the winching angle to
be฀changed฀if฀a฀suitable฀anchor฀point฀can’t฀be฀found฀in฀a฀straight line in front of the vehicle.
Recovery Hook
This is a universal heavy duty recovery hook can be
mounted to a suitable point on a vehicles chassis for
vehicle recovery. It can also be used for anchoring the
hook end of the cable to the vehicle when using a
snatch block.
Synthetic Rope
Synthetic rope is an alternative to steel cable. It is much
lighter than steel cable. It is much safer than steel cable
if it snaps under extreme load because it will not whip
potentially฀causing฀injury฀or฀damage.฀It฀is฀able฀to฀be฀spliced back together if it was to snap.
Alloy Hawse Fairlead
An฀alloy฀hawse฀fairlead฀is฀essential฀if฀using฀a฀synthetic฀rope. It prevents the rope being caught between
the rollers and sustaining damage if used with a
conventional roller fairlead.
Roller Fairlead
The use of a roller fairlead assists in guiding the steel
cable฀onto฀the฀cable฀drum,฀minimising฀damage฀to฀the฀cable itself.
25

WINCH ACCESSORIES
Rugged Rescue Survival Kit
This฀is฀a฀versatile฀8-in-1฀kit฀that฀can฀help฀you฀out฀in฀a variety of situations.
Kit฀includes:
•฀Tree฀saw฀•฀Pick
•฀Mallet฀•฀Shovel
•฀Axe฀฀•฀1/12”฀socket฀drive
•฀2฀x฀tyre฀levers฀•฀Flat฀pack฀funnelAlso included is a long and short handle.
Small Recovery Bag
This heavy duty bag is an ideal way to store your
recovery gear.
Large Recovery Kit
This kit is contained in a heavy duty bag and has the
majority฀of฀the฀winch฀accessories฀you฀will฀require฀to฀get฀the most out of your winch.
The฀kit฀includes:
•฀9m฀x฀8000kg฀snatch฀strap
•฀20m฀x฀4500kg฀winch฀extension
•฀3m฀x฀8mm฀drag฀chain
•฀2฀x฀4.7t฀bow฀shackles
•฀Snatch฀block
•฀Heavy฀duty฀winching฀glovesBow Shackle 4.75T
These shackles are designed and rated for the heavy
loads that can exerted on them during vehicle recovery.
Small Recovery Kit
This kit is contained in a heavy duty bag and has
equipment that can be used for vehicle to vehicle recovery
without winching.
The฀kit฀includes:
•฀9m฀x฀8000kg฀snatch฀strap
•฀2฀x฀4.7t฀bow฀shackles
•฀4.7t฀recovery฀hitch.
•฀Heavy฀duty฀winching฀gloves.Speedy Deflator
In some cases a vehicle can be driven out of boggy or soft
terrain without having to winch by simply letting the tyres
down to a lower pressure. This can be done quickly and
easily฀with฀an฀Ironman฀speedy฀deator.฀Winching Gloves
Sturdy winching gloves are essential for hand protection
when winching or handling winch cable.
Flomax / Flomax Pro
The฀Flomax฀air฀compressor฀is฀a฀versatile,฀portable,฀12v compressor that can be used for many
applications฀including฀re-inating฀your฀tyres฀after฀a฀days฀four฀wheel฀driving.฀It฀ows฀72L฀per฀minute,฀150PSI฀maximum฀pressure฀and฀has฀a฀3฀year฀warranty.
The Flomax Pro portable air compressor gets the
job฀done฀fast.฀It฀ows฀160L฀per฀minute,฀150PSI฀maximum and has a 3 year warranty.
Recovery Hitch & Bow Shackle
This฀is฀a฀removable฀recovery฀point฀that฀ts฀into฀the฀hitch฀receiver of most heavy duty tow bars and allows the
vehicle to be recovered from behind.
27

TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
Winch฀won’t฀workFlat battery in vehicle Replace฀or฀recharge฀battery
NOTE:฀Winch฀should฀always be connected
to the main battery not
auxiliary
Flat battery in wireless
remote controller Replace฀battery฀or฀use฀plug-in฀controllerWinch has been wired
incorrectly Check฀all฀wiring฀as฀per฀diagram in installation
pages of this manual
Poor motor earth Make sure earth cable
for motor is connected to
main battery
Poor control box earth Mare sure small earth
wire for control box is
securely connected to a
good฀earth฀(eg.฀Earth฀stud฀on฀winch฀motor)Wireless฀activator฀or฀plug-in hand controller are not
connected to control box Connect฀wireless฀activator฀or plug in hand controller to control box and make
sure that hand controller
is switched to correct
mode.
Hand controller will not
operate
Incorrect mode selected
on hand controller
Select wireless or plug in
mode on hand controller
Winch works in wrong
direction Cable฀spooled฀in฀the฀wrong direction on the
drum
Make sure that cable is
spooled on in the direction
indicated on winch
housing
Winch has been wired
incorrectly Check฀all฀connections฀on motor as per wiring
diagram in installation
pages of this manual
PROBLEM POSSIBLE CAUSE SOLUTION
Winch will only work in
one direction
Winch has been wired
incorrectly Check฀all฀connections฀on motor as per wiring
diagram in installation
pages of this manual
Brake will not hold on hills Cable฀spooled฀on฀in฀the฀wrong direction on drum Make sure that cable is
spooled on in the direction
indicated on winch
housing
Clutch฀handle฀is฀difcult฀to rotate Load has not been
released from cable Using฀hand฀controller,฀spool cable out slightly to
release the load from the
cable
Winch motor gets hot
during winching
This is quite normal Winch needs to be
checked regularly during
winching.฀With฀bare฀hand,฀if it is uncomfortably
warm฀to฀touch,฀cease฀winching until it has
cooled down
Winch฀will฀not฀free-spoolClutch฀handle฀is฀in฀the฀‘Engage’฀positionRotate฀handle฀to฀the฀‘Disengage’฀positionUneven winch mounting
surface
Make sure that winch
mounting฀surface฀is฀at฀and not distorted and that
winch mounting bolts are
tight
Winch motor operates but
cable drum does not turn Clutch฀handle฀is฀in฀the฀‘Disengaged’฀positionRotate฀handle฀to฀the฀‘Engage’฀positionFurther Enquiries
For further assistance please contact your place of purchase.
29

WARRANTY
Ironman 4x4 will provide warranty to the original purchaser and only the original purchaser of
the Ironman Monster Winch under the following conditions;
฀Ironman฀4x4฀will฀warrant฀against฀manufacturing,฀mechanical฀or฀electrical฀defects,฀and฀defects฀in material and workmanship for a period of 3 years from original purchase date.
To฀obtain฀warranty,฀Ironman฀4x4฀or฀an฀authorised฀agent฀there฀of฀must฀be฀provided฀with฀proof฀of฀purchase.฀This฀warranty฀does฀not฀cover฀the฀removal฀or฀re-installation฀of฀the฀winch.Ironman฀4x4฀reserves฀the฀right,฀at฀its฀option,฀to฀repair,฀replace฀or฀refund฀the฀purchase฀price฀of฀a faulty or defective winch or its components if returned to the place of purchase during the
warranty period.
When returning a winch for warranty assessment it must be accompanied with the customers
name,฀address,฀contact฀phone฀number,฀a฀clear฀description฀of฀the฀fault฀and฀a฀copy฀of฀the฀original sales receipt detailing the date of purchase.
This฀warranty฀does฀not฀apply฀to฀wire฀or฀synthetic฀rope,฀nish฀of฀winch฀or฀if฀the฀winch
has฀been฀damaged฀due฀to฀accident,฀misuse,฀abuse,฀misapplication,฀overloading,฀collision,฀modication,฀improper฀installation฀or฀lack฀of฀or฀improper฀servicing.฀Industrial฀or฀commercial฀use,฀lifting฀or฀hoisting฀with฀winch฀will฀also฀void฀the฀warranty.THE฀WARRANTY฀SET฀FORTH฀ABOVE฀IS฀THE฀ONLY฀WARRANTY.฀THERE฀ARE฀NO฀OTHER฀WARRANTIES,฀INCLUDING฀BUT฀NOT฀LIMITED฀TO฀IMPLIED฀WARRANTIES฀OR฀MERCHANT฀ABILITY฀OR฀FITNESS฀FOR฀A฀PARTICULAR฀PURPOSE.ANY฀IMPLIED฀WARRANTY฀WHICH฀BY฀LAW฀MAY฀NOT฀BE฀EXCLUDED฀IS฀LIMITED฀IN฀DURATION฀TO฀THREE฀(3)฀YEARS฀FROM฀THE฀DATE฀OF฀THE฀ORIGINAL฀RETAIL฀PURCHASE฀OF฀THE฀PRODUCT.NO฀IRONMAN฀4X4฀DEALER,฀฀AGENT฀OR฀EMPLOYEE฀IS฀AUTHORISED฀TO฀MAKE฀ANY฀MODIFICATION,฀EXTENSION฀OR฀ADDITION฀TO฀THIS฀WARRANTY.IRONMAN฀4X4฀SHALL฀NOT฀BE฀LIABLE฀FOR฀SPECIAL,฀INDIRECT,฀INCIDENTAL฀OR฀CONSEQUENTIAL฀DAMAGES฀(INCLUDING,฀BUT฀NOT฀LIMITED฀TO,฀LOST฀PROFITS,฀DOWN฀TIME฀OR฀LOSS฀OF฀USE)฀UNDER฀ANY฀LEGAL฀THEORY,฀EVEN฀IF฀IRONMAN฀4X4฀WAS฀ADVISED฀OF฀THE฀POSSIBILITY฀OF฀SUCH฀DAMAGES.IRONMAN฀4X4฀RESERVES฀THE฀RIGHT฀TO฀CHANGE฀PRODUCT฀DESIGN฀WITHOUT฀NOTICE.฀IN฀SITUATIONS฀IN฀WHICH฀IRONMAN฀4X4฀HAS฀CHANGED฀A฀PRODUCT฀DESIGN,฀IRONMAN฀4X4฀SHALL฀HAVE฀NO฀OBLIGATION฀TO฀UPGRADE฀OR฀OTHERWISE฀MODIFY฀PREVIOUS฀MANUFACTURED฀PRODUCTS.Warranty Terms & Conditions
31