Ironton 54126 User manual

SAVE THESE INSTRUCTIONS
12,000-Lb. 12V DC Electric Truck Winch
Owner’s Manual
WARNING: Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety
precautions may result in serious personal injury.
Item #54126

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Thank you very much for choosing an Ironton™product!
For future reference, please complete the owner’s record below:
Serial Number/Lot Date Code: ________________________________
Purchase Date: ____________________________________________
Save the receipt, warranty, and this manual. It is important that you read
the entire manual to become familiar with this product before you begin
using it.
This electric truck winch is designed for certain applications only.
Northern Tool & Equipment is not responsible for issues arising from
modification or improper use of this product such as an application for
which it was not designed. We strongly recommend that this product not
be modified and/or used for any application other than that for which it
was designed.
For technical questions, please call 1-800-222-5381.

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Table of Contents
Intended Use..........................................................................................................................................4
Technical Specifications......................................................................................................................4
Important Safety Information...............................................................................................................5
Specific Operation Warnings...............................................................................................................6
Assembly Instructions..........................................................................................................................8
Before Each Use..................................................................................................................................10
Operating Instructions........................................................................................................................10
After Each Use.....................................................................................................................................14
Maintenance ........................................................................................................................................14
Troubleshooting..................................................................................................................................14
Parts Diagram......................................................................................................................................16
Parts List..............................................................................................................................................16
Replacement Parts..............................................................................................................................17
Limited Warranty.................................................................................................................................18

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Intended Use
The Ironton 12,000-Lb. 12 Volt DC Electric Truck Winch has a cable tensioner to prevent cable
tangling. The series-wound motor stays cooler during long pulls. The three-stage planetary gear
system provides fast line speed. The automatic load-holding brake insures maximum safety. The
freespooling provides a fast line-out while the 12 ft. ergonomic handheld remote control. The winch
contains a roller fairlead with nylon bushing and an aircraft-grade wire rope
Technical Specifications
Property
Specification
Rated Single
Line Pull
12,000 Ib. (5454 kg.)
Application
Vehicle Recovery / For Trucks and SUVs
Motor
12V DC 6 HP Series Wound
Power In & Power Out
Yes
Duty Cycle Rating
5% (45 sec at Max Rated Load;
14min, 15 sec Rest)
Pendant Controller
Wired, 12 ft (3.7m) Long
Gear Train
3-stage Planetary
Gear Ratio
265:1
Freespool
Sliding Ring Gear
Brake
Auto Load Holding
Drum (Dia. XL)
2.5" X 8.8"(64mmX224 mm)
Clevis Hook
3/8”, Replaceable with Spring-Loaded Safety Latch
Fairlead
Roller with Nylon Bushings
Wire Rope Size /Type
0.375" x 65 ’ (9.5 mm X 19.8 m )
Nominal Strength=14,000 Ib.
7X19 Galvanized Steel
Aircraft Wire Rope
Battery
12V DC Minimum650 CCA
Battery
Cables
Min. 3.5Gauge
Mounting Bolt Pattern
10’’x 4.5’’(254mm x 114.3mm)
Mounting Hardware
Winch:4xG8, M12-1.75X25mm
Fairlead: 2xG8.M10-1.50X 30mm
Solenoid Box: 2xG8.ST-M5X 14mm
Overload Protection
Inline Circuit Breaker
Sound Rating
85 dB
Overall Dimensions
(LXDX H)
21" X 6.4" X 8.3’’
Weight
86.8 Ib. (39.4kg)
IP Rating
IP66-Winch and Controls (resistant to powerful water jets, except remote
control switch)

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Important Safety Information
⚠WARNING
Read and understand all instructions. Failure to follow all instructions may result in fire, serious
injury and /or DEATH.
The warnings, cautions, and instructions in this manual cannot cover all possible conditions or
situations that could occur. Exercise common sense and caution when using this electric winch.
Always be aware of the environment and ensure that the electric winch is used in a safe and
responsible manner.
Do not allow persons to operate or assemble the electric winch until they have read this manual
and have developed a thorough understanding of how it works.
Do not modify this electric winch in any way. Unauthorized modification may impair the function
and/or safety and could affect the life of the electric winch. There are specific applications for
which the electric winch was designed.
Use the right tool for the job. DO NOT attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this electric winch was designed.
The tool will be a safer and do the job better at the capacity for which it was intended. DO NOT
use this equipment for a purpose for which it was not intended.
Industrial or commercial applications must follow OSHA requirements.
⚠WARNING
This product may contain chemicals known to the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.
⚠WARNING
WORK AREA SAFETY
Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.
Cluttered, wet, or dark work areas can result in injury. Using the electric winch in confined work
areas may put you dangerously close to other cutting tools and rotating parts.
Keep children and bystanders away from the work area while operating the tool. Do not allow
children to handle the electric winch.

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⚠WARNING
PERSONAL SAFETY
Stay alert, watch what you are doing, and use common sense when operating the electric winch.
Do not use the electric winch while you are tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating the tool may result in serious personal injury.
Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair, clothing
and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving
parts. Air vents on the tool often cover moving parts and should be avoided.
Wear the proper personal protective equipment when necessary. Use ANSIZ87.1 compliant safety
goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in
dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection systems,
and hearing protection when appropriate. This applies to all persons in the work area.
Do not overreach. Keep proper footing and balance at all times.
⚠CAUTION
WINCH USE AND CARE
Inspect before every use, do not use if damaged or parts loose. Examine the winch for structural
cracks, bends, damage, frayed or kinked wire rope, and any other conditions that may affect the
safe operate of the winch. Do not use the winch even if minor damage appears. A kink
permanently weakens the wire rope, even after it is straightened out; kinked wire rope can fail
suddenly and must not be used.
Do not force the winch. Products are safer and do a better job when used in the manner for which
they are designed. Plan your work, and use the correct product for the job.
Store the winch when it is not in use. Store it in a dry, secure place out of the reach of children.
Inspect the tool for good working condition prior to storage and before re-use.
Use only accessories that are recommended by the manufacturer for use with your product.
Accessories that may be suitable for one product may create a risk of injury when used with
another tool. Never use an accessory that has a lower operating speed or operating pressure than
the tool itself.
Specific Operation Warnings
⚠WARNING
GENERAL SAFETY
To prevent injury or property damage, read and understand all instructions before operating
winch.
Wear ANSI Z87.1 compliant safety goggles and heavy duty leather work gloves during
operation.
Do not exceed the rated load capacity. Be aware of dynamic loading! Sudden load movement
may briefly create excess load causing product failure.
INSTALLATION SAFETY

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Choose a mounting location that can support the winch and rated load capacity.
Do not weld mounting bolts
Use supplied power cords and wire rope listed in manual only. Do not use thinner/longer cables
or link multiple cables together.
Keep hands clear of winch rope, hook loop, hook and fairlead opening during installation,
operation, and when spooling in or out.
Wrap the wire rope under 500 lbs. of tension before use. Otherwise, the wire rope may bind
during operation.
Do not route electrical cables near sharp edges or parts that will move or become hot.
Ventilate area well before and while working on battery. Explosive hydrogen gas can
accumulate and explode when ignited by a spark or open flame.
Only connect to a clean, corrosion free battery.
Remove all jewelry and metallic objects before working near battery.
WINCHING SAFETY
Inspect winch rope, hook, and slings before operating winch. Frayed, kinked or damaged winch
rope must be replaced immediately. Damaged components must be replaced before operation.
Do not maintain power to the winch if the motor stalls. Verify the load is within the rated capacity
for the wire rope layer. Make sure the battery is fully charged. Use double line rigging whenever
possible.
Do not engage or disengage clutch while under load.
Always ensure hook latch is closed and not supporting load.
Never apply load to hook tip or latch. Apply load only to the center of hook.
Never use a hook whose throat opening has increased, or whose top is bent or twisted.
Keep clear of fairlead when operating. Do not try to guide wire rope.
Do not place any fingers through the hook. Fingers may be caught and get pulled into the
fairlead or drum. Use the included strap to hold the hook instead.
Stay out of the direct line that the wire rope is pulling. If it slips or breaks, it will create a whiplash
effect. Utilize a winch dampener to help absorb the force released if the wire rope breaks.
Do not use for overhead hoisting. This winch is intended to be used for pulling only.
Use a spotter to assist you in ensuring that it is safe to operate the winch. Make sure the spotter
is out of the way of the vehicle and the wire rope before activating the winch.
Do not use the hand crank, if equipped, to assist the winch.
Do not use vehicle to pull on the wire rope and “assist” the winch.
Do not use to transport people or animals.
Disconnect battery cables before working near the wire rope, drum, fairlead or load, to prevent
accidental starting.
Keep wire rope straight to avoid kinking the wire rope.
Keep children and bystanders away while operating.
Hook onto the object using a pulling point, tow strap or chain. Do not wrap the wire rope around
the object and hook onto the wire rope itself.
Do not use a recovery strap while winching.
Secure the load after moving. Do not lock the mechanism.

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Keep at least 5 full turns of wire rope on the drum.
Keep clear of the wire rope, hook, and load while winching. Do not step over the wire rope. Do
not push sideways against the wire rope under tension; wire rope might break under this load
and recoil back, striking the person pushing against it or a bystander.
If the wire rope begins to get entangled, stop the winch immediately and release the wire rope
using the switch.
Only winch with the winching vehicle’s transmission placed in neutral. Winching with a vehicle’s
transmission in gear or park may damage the transmission. A vehicle’s transmission is not
designed to handle this type of load.
Do not operate the winch on extreme slopes. Do not exceed the angles for a roller fairlead. For
a hawse fairlead, the angle should be as close to 180 degrees as possible.
People with pacemakers should consult their physicians before use. Electromagnetic fields in
close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.
Remove any element or obstacle that may interfere with safe operation of the winch.
Always use supplied hook strap whenever spooling winch rope in or out, during installation and
during operation.
Always take time to use appropriate rigging techniques for winch pull.
Assembly Instructions
⚠WARNING
Read the entire Important Safety Information section at the beginning of this manual including all
text under subheadings before set up or use of this electric winch.
Mounting the Winch:
1. The mounting plate must be rated to at least the winch’s capacity.
2. Align the winch perpendicular to centerline of the vehicle at the desired location a nd mark the
locations of the winch base holes. Compare the dimensions of the marked holes.
3. Before drilling, verify that the installation surface has no hidden components or structural pieces that
will be damaged.
NOTE: This winch can generate extreme forces . Select a location that can withstand threated
capacity without damage or weakening. Steel reinforcement plates may be needed or a certified
welder may need to weld on additional bracing depending on the mounting location.
4. Drill holes appropriate for the hardware at the marked locations.
5. Install the winch using hardware described under the specifications table.

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Mounting the Solenoid Assembly:
1. Place the solenoid box in a suitable place close enough to the winch to allow the cable to be routed
properly.
2. Mark the desired location of the screw holes.
3. Verify that the installation surface has no hidden components or structural pieces that will be damaged
before drilling.
4. Drill pilot holes for the mounting screws.
5. Secure in place with mounting screws.
Wiring:
To prevent serious injury from explosion, due to sparking at the battery connection, disconnect the
Battery Cables before making other wiring connections.
To prevent serious injury from leaking battery acid, do not use a dirty, corroded, or leaking battery.
Only use a 12V automotive (or equivalent) battery, in good condition.
1. Plan a route for the wiring from the point of the vehicle where the winch will be
mounted, or used, to the battery. This route must be secured and out of the way of
moving parts, road debris, or any possibility of being damaged by operation or
maintenance of the vehicle. For example , you may wish to route the wires under the
vehicle , attaching it to the frame using suitable fasteners Do not attach the wires to
the exhaust system, drive shaft, emergency brake cable, fuel line, or any other
components which may create damage to the wiring through heat or motion, or
create a fire hazard.
2. If you drill through the bumper or any part of the body to route the wires, be sure to
install a rubber grommet in the hole to prevent fraying of the wires at that point.
3. Route the Cables from the Solenoid to the battery and from the Solenoid to the winch,
following the precautions discussed. See the following picture.

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4. Attach the red, black and yellow cables to the terminals on the winch. The winch
terminals are color coded.
5. Attach the circuit breaker to the positive terminal on the battery.
6. Attach the red battery cable to the circuit breaker.
7. Attach the black battery cable directly to the negative terminal of the battery.
8. Lift the socket cover exposing the electrical switch connector. Insert the pendant
connector into the socket.
NOTE: The attachment of the Motor Cables determines the operation
of the Remote's button. After the unit is mounted and powered, check
the direction of the Power In and Power Out on the Remote button. If
you wish to change the direction on the Remote, disconnect the
Battery Cables from the battery, switch the Motor Cable connections
on the Motor Assembly, then reconnect the Battery Cables.
9. Disconnect the pendant controller when not in use.
Preparing the Wire Rope:
1. The wire rope must be properly coiled under tension to be able to support a load without damage.
2. Uncoil the wire rope, expect for 5 full wraps.
3. Recoil the rope back into the winch under at least 500 lb. of tension.
Before Each Use
⚠WARNING
Inspect winch rope, hook, and slings before operating winch. Frayed, kinked or damaged winch
rope must be replaced immediately. Damaged components must be replaced before operation.
Wrap the wire rope under 500 lbs. of tension before use. Otherwise, the wire rope may bind
during operation.
Ventilate area well before and while working on battery. Explosive hydrogen gas can
accumulate and explode when ignited by a spark or open flame.
Remove all jewelry and metallic objects before working near battery.
Operating Instructions
⚠WARNING

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•Read the entire Important Safety Information section at the beginning of this manual, including
all text under subheadings before set up or use of this electric winch.
•The instructions that follow are basic guidelines only and cannot cover all situations
encountered during use. The operator and assistants must carefully plan usage to prevent
accidents.
1. Examine the wire rope. Do not use the winch if the wire rope is frayed, kinked, or damaged.
2. Fully charge the vehicle’s battery.
3. Check the winch's electrical connections. AII connections must be tight and clean.
4. Put the vehicle's transmission in Neutral.
5. If the vehicle where the winch is mounted is not supposed to be moved, engage the emergency
brake and block the wheels using wheel chocks (sold separately.)
6. To pull out the wire rope, move the clutch control to the released position, shown below. Slide the
loop of the hook strap over the hook, and then pull on the hook strap to pull out the wire rope.
7. Hook onto the object using a pulling point, tow strap, tree strap, or chain. See the following
picture.
⚠WARNING
Leave at least five full turns of wire rope on the drum.
Do not wrap the wire rope around the object and hook onto the wire rope itself.
This can damage the object being pulled, and kink or fray the wire rope.

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8. Attachment point must be centered in loop of hook and the hook’s safety clasp must be fully
closed. See the following picture.
9. Do not use a recovery strap while winching. They are designed to stretch and can suddenly whip
back towards the operator during a winching operation.
10. Place a heavy rag or carpet (sold separately) over the wire rope span, 6 feet from the hook to
help absorb the force released if the wire rope breaks.
11. Re-engage the clutch by moving the clutch handle to the engaged position, see the following
picture.
⚠WARNING
Do not allow anyone to stand near the wire rope or in line with the wire rope behind the winch while
it is under power. If the wire rope should slip or break, it can suddenly whip back towards the winch,
causing a hazard for anyone in the area. Stand far to the side while winching.
12. Attach the pendant controller to the socket on the solenoid assembly. See the following picture.

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13. Operate the pendant controls briefly to ensure they work properly. If operation is reversed, the
power cables may be connected backwards. Correct any such issue before use.
14. When it is safe to do so, use the power switch on the pendant controller to retract the wire rope,
and winch the item as desired. Do not power the hook all the way into the fairlead to prevent
damage.
15. Do not operate the winch at extreme angles. Do not exceed the angles shown below for a roller
fairlead. For a hawse fairlead, the angle should be as close to straight as possible.
16. If the object to be pulled must be pulled at an angle in relation to the winch, use a pulley (sold
separately) and an anchor point directly in front of the winch, as shown in the following picture, to
keep the wire rope pull straight.
⚠WARNING
Stop the winch and release tension on the wire rope before moving the rag or carpet placed on it.
17. Do not continue use of the winch until the battery is completely run down.
18. You may wish to keep the engine running while using this winch, to continually recharge the
battery. However, exercise extreme caution when working around a running vehicle and ONLY
operate a vehicle in an outdoor area.
19. When finished pulling the load, reverse the direction of the winch just enough to release tension
on the wire rope so that you can unfasten the hook from the load and reel in the wire rope.

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Duty Cycle (Duration of Use):
Avoid damage to the winch by not winching for more than the prescribed duty cycle time.
The Duty Cycle defines the amount of time, within a 15 minute period, during which a winch can
operate at its maximum capacity without overheating.
For example, this winch with a 5% duty cycle at its maximum load must be allowed to rest for at least
14 minutes, 15 seconds after every 45 seconds of continuous operation. Failure to carefully observe
duty cycle limitations can easily over-stress a winch contribution to premature winch failure.
After Each Use
⚠WARNING
Wipe external surfaces of the winch with a clean cloth.
Maintenance
⚠WARNING
•To prevent serious injury from accidental operation: disconnect the battery cables before
performing any inspection, maintenance, or cleaning procedures.
•To prevent serious injury from winch failure: do not use damaged equipment. If an abnormal
noise or vibration occurs, have the problem corrected before further use.
•Lubricate the wire rope occasionally with a light oil.
•The winch‘s internal mechanism is permanently lubricated. Do not open the housing. However,
if the winch is submerged, it should be opened, dried, and re-lubricated by a qualified technician
as soon as possible to prevent corrosion.
Troubleshooting
⚠WARNING
•Follow all safety precautions whenever diagnosing or servicing the tool.
•Disconnect power supply before service.

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Use the table below to troubleshoot problems before contacting service personnel or your local
dealer. If the problem continues after troubleshooting, call your local dealer for assistance.
Failure
Possible Cause
Corrective Action
Motor
overheats
1. Incorrect power cords
2. Winch running time too long
1. Use only supplied power cords
2. Allow winch to cool down periodically
Motor does
not turn on
1. Switch assembly not connected
properly.
2. Loose battery cable connections
3. Vehicle battery needs charging
4. Solenoid malfunctioning
5. Defective switch assembly
6. Defective motor
7. Water has entered motor
8. Internal damage or wear
1. Insert switch assembly all the way into
connector.
2. Tighten nuts on all cable connections
3. Fully charge battery
4. Tap solenoid to loosen
contacts. Apply 12 volts to coil
terminals directly. A clicking
indicates proper activation
5. Replace switch assembly
6. Check for voltage at armature port
with switch pressed. If voltage is
present, replace motor
7. Allow to drain and dry. Run in
short bursts without load until
completely dry
8. Have technician service winch
Motor runs
but wire rope
drum does
not turn
Clutch not engage
Move the Clutch Handle to the Engaged
position. If problem persists contact a
qualified technician to check and repair unit.
Motor runs
slowly or
without
normaI
power
1 Insufficient current or voltage
2.Loose or corroded battery
cable connections
3.Incorrect power cords
1. Battery weak, recharge
Run winch with vehicle motor running
2. Clean, tighten, or replace
3. Use only supplied power cords
Motor runs in
one direction
only
1. Defective or stuck solenoid
2. Defective switch assembly.
1. Tap solenoid to loosen contacts
2. Repair or replace solenoid
3. Replace switch assembly

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Parts Diagram
Parts List
Part Number
Description
Quantity
1
Hex Socket FH Screw M4x20
10
2
Lock Washer Ø4
22
3
Gearbox End Cover
1
4
Washer
2
5
Bearing
1
6
Sun Gear (Input)
1
7
Clutch Handle Assembly
1
8
Gear Box Tube
1
9
Clutch Gear
1
10
Gear Carrier Assembly (Input)
1
11
Gear Carrier Assembly (Intermediate)
1
12
Washer
1
13
Gear Carrier Assembly (Output)
1

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Part Number
Description
Quantity
14
Tie Bar Screw M8x25
4
15
Tie Bar Washer Ø8x0.5
4
16
Gear Box Base
1
17
Hex Socket FH Screw M4x18
10
18
Nylon Bearing
2
19
Seal Kit
2
20
Drum Assembly
1
21
Screw M8x10
2
22
Torsional Spring (Left)
1
23
Short Roller
2
24
Roller Shaft
1
25
Pressing Plate (Left)
1
26
Long Roller
1
27
Pressing Plate (Right)
1
28
Tie Bar
1
29
Torsional Spring (Right)
1
30
Motor Assembly
1
31
Winch Mounting Hardware
4
32
Brake Assembly
1
33
Wire Rope
1
34
Clevis Hook
1
35
Red Strap
1
36
Roller Fairlead
1
37
Fairlead Mounting Hardware
2
38
Control Box
1
39
Pendant Controller
1
40
Power Wire
1
41
Circuit Breaker
1
Replacement Parts
For replacement parts and technical questions, please call Customer Service at 1-800-222-5381.
Not all product components are available for replacement. The illustrations provided are a
convenient reference to the location and position of parts in the assembly sequence.
When ordering parts, the following information will be required: item description, item model
number, item serial number/item lot date code, and the replacement part number.
The distributor reserves the rights to make design changes and improvements to product lines
and manuals without notice.

Page 18 of 19
Limited Warranty
Northern Tool and Equipment Company, Inc. ("We'' or '"Us'') warrants to the original purchaser only
("You'' or “Your”) that the Ironton product purchased will be free from material defects in both
materials and workmanship, normal wear and tear excepted, for a period of one year from date of
purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in
accordance with product instructions. There are no other warranties, express or implied, including the
warranty of merchantability or fitness for a particular purpose. If the product does not comply with this
limited warranty, Your sole and exclusive remedy is that We will, at our sole option and within a
commercially reasonable time, either replace the product or product component without charge to You
or refund the purchase price (less shipping). This limited warranty is not transferable.
Limitations on the Warranty
This limited warranty does not cover: (a) normal wear and tear; (b) damage through abuse, neglect,
misuse, or as a result of any accident or in any other manner; (c) damage from misapplication,
overloading, or improper installation; (d) improper maintenance and repair; and (e) product alteration
in any manner by anyone other than Us, with the sole exception of alterations made pursuant to
product instructions and in a workmanlike manner.
Obligations of Purchaser
You must retain Your product purchase receipt to verify date of purchase and that You are the original
purchaser. To make a warranty claim, contact Us at 1-800-222-5381, identify the product by make
and model number, and follow the claim instructions that will be provided. The product and the
purchase receipt must be provided to Us in order to process Your warranty claim. Any returned
product that is replaced or refunded by Us becomes our property. You will be responsible for return
shipping costs or costs related to Your return visit to a retail store.
Remedy Limits
Product replacement or a refund of the purchase price is Your sole remedy under this limited warranty
or any other warranty related to the product. We shall not be liable for: service or labor charges or
damage to Your property incurred in removing or replacing the product; any damages, including,
without limitation, damages to tangible personal property or personal injury, related to Your improper
use, installation, or maintenance of the product or product component; or any indirect, incidental or
consequential damages of any kind for any reason.
Assumption of Risk
You acknowledge and agree that any use of the product for any purpose other than the specified
use(s) stated in the product instructions is at Your own risk.
Governing Law
This limited warranty gives You specific legal rights, and You also may have other rights which vary
from state to state. Some states do not allow limitations or exclusions on implied warranties or
incidental or consequential damages, so the above limitations may not apply to You. This limited
warranty is governed by the laws of the State of Minnesota, without regard to rules pertaining to
conflicts of law. The state courts located in Dakota County, Minnesota shall have exclusive jurisdiction
for any disputes relating to this warranty.

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Distributed by:
Northern Tool & Equipment Company, Inc.
Burnsville, Minnesota 55306
www.northerntool.com
Made in China