Mile Marker PE2000 User manual

Electric Winch
Installation & Operation Manual
PE 2000
12 VOLT DC ATV WINCH (P/N: 76-50100)
PERMANENT MAGNET MOTOR
76-50100
2121 Blount Road * Pompano Beach, Fl 33069 * USA
Toll Free: 1-800-886-8647 Local: 1-954-782-0604
Fax: [phone] Email: [e-mail]
Website: http://www.milemarker.com

Model PE 2000
P/N 76-50100
Features:
Planetary gear system for fast line speed
Free spooling
Power IN and Power OUT
1.5Hp (1kw) heavy duty electric permanent magnetic motor
Low electric current
Specifications:
Rated Line Pull 2000 lbs. (907kg) Single Line
Gear Reduction Ratio 153:1
Motor (Permanent Magnet)1.5Hp(1kw), 12 Volt DC
Drum Size (Diameter x Length) 2.56” x2.86” (65.02mm x 72.64mm)
Cable supplied(min. Break force 4200lbs.) 5/32” (4mm) x 50 ft. (15.2m)aircraft cable with replaceable hook
Overall Dimension(LengthxWidthxHeight) 12.21” x 4.13” x 4.35”(310.13mm x 104.9mm x 110.49mm)
Net Weight 14.6 lb (6.6kg)
Mounting bolt pattern T-Shaped 3”(76.2mm) x 1.9”(48.3mm)
Line Pull & Cable Capacity by Layer Performance of 1st Layer
Rated Line Pull Cable Capacity
Cable
Layer lbs kgs ft meters
1 2000 907 6 1.8
2 1636 742 13 4
3 1385 628 22 6.7
4 1200 544 33 10
5 1059 480 44 13.4
6 947 430 50 15
LinePull LineSpeed MotorCurrent
lbs kgs fpm mpm 12VAmp
0 0 16.4 5.0 15
500 227 13.1 4.0 45
1000 454 9.8 3.0 73
1500 680 6.2 1.9 114
2000 907 4.9 1.5 140
1

Safety Warnings & Precautions
Do not operate winch under influence of drugs or alcohol.
Read manual before using any winch.
Always use heavy gloves when handling wire rope.
Never hook the cable back upon itself. The cable can break under tension
and cause injury and damage.
Stay clear of wire rope and keep others away during winch operation or
when there is a load on the wire rope.
Inspect winch and wire rope before each use. Do not use winch if wire rope
or winch shows wear or damage.
Replace any parts as needed before using the winch.
Do not exceed the winch capacity.
Do not place hands near the fairlead when winch is in operation. Always use
the protective hand strap.
Do not use the winch as a hoist or to move people.
Do not use winch to secure a load or to tow vehicles.
Do not submerge winch in water.
Avoid injury and property damage, be safe and think first before operating
winch. Use common sense.
Electric winch is for intermittent use only, 12 V DC.
Look to see where the drill bit will come through before drilling holes for
installation. Never drill into the gas tank or electrical wiring.
Unpacking
When unpacking, check to make sure that all of the parts listed on Page 6 are
included. If any parts are missing or broken, please call Mile Marker at the
number located on the cover of this manual as soon as possible.
2

Installation Instructions
When installing a winch, your installation may vary from
the manual diagrams and instructions included here due
to vehicle variations and mounting options in the structure.
Always disconnect the battery from the vehicle to avoid
electric hazzard.
If you choose not to use an ATV mounting kit
you may be required to drill holes in the structure to
support the load. Be sure the location will be
strong enough to support the rated pulling force of
the winch. Do not drill into wiring or gas tank!
If the mounting bolts needed are of different length
than those supplied, use a bolt of equal or better quality
to that supplied by Mile Marker. Torque the provided
5/16” Grade 5 mounting bolts to 12 ft lbs.(1.7kg-m)
Step #1
Line up the winch on the vehicle mounting frame (not provided). Make drill
markings throughout the mounting holes. Winch should be aligned & secured to a
solid, flat part of the vehicle (capable of supporting the winch and load
capacity) where the full rated load will be evenly distributed. Also, please
remember that the winch is designed for horizontal pull, not vertical pull.
Step #2
Before drilling the (3) 5/16 inch holes through the vehicle mounting frame, remove the
winch. Drill the holes at this time. Secure the winch to the vehicle mounting
frame with the correct hardware. Tighten securely at this time.
Step #3
Remove the outer connection nuts from the winch motor; connect the red cable
(+) to the red terminal and the black cable (-) to the black terminal.
Tighten the connections.
Property damage or serious injury may occur if this winch is
mounted or wired incorrectly. Therefore, installation should be
done by a qualified technician.
Step #4
Connect the red & black Remote Control-to-Battery cables (marked as “Battery” on
the cables) to the 12 volt battery fuse box terminal strip on the vehicle in accordance
with Step#5. The circuit fuse must be 70 amps and the circuit must be 12 volt.
Remote control battery cables should not be drawn taut. Leave
slack for some cable flexibility. Do not put cables near moving
engine parts or heated areas that could melt the cable
insulation.
Step #5
Disconnect the positive (red) cable from the vehicle battery. You will now be making
an electrical connection from the Remote Control-to-Battery cables to the vehicle
electrical system (the vehicle’s fuse box terminal strip)
NOTE: Even though the 12 volt battery cannot shock you, it may spark
and heat up to the melting point. It may cause serious burns if
not installed and fused correctly. Due to these factors, it is imperative
to have the battery disconnected at this time.
3

Installation Instructions(Continued)
Step #6
Find an appropriate positive (red) fused terminal point in the vehicle fuse box that is able
to supply 70 amps of current and connect the red Remote Control-to-Battery
cable directly to the fuse terminal (without cutting wires). Connect the negative (black)
cable to the vehicle metal frame or a ground lug on or near the battery. Re-connect the
positive (red) battery cable to the battery. Unfasten the clutch by pulling out, then turn
the Clutch Knob to lock it in the OUT position.
Step #7
Pull the cable 5 feet out for testing purposes. Test Utility winch for proper operation.
Refer to the operation section below.
Operation Instructions
NOTE: The vehicle battery must be fully charged and the engine
running before using the winch.
1. The clutch should be in the OUT position (refer to Step # 6 in
the Installation Instructions).
2. Grab the hook with the manual handle and pull out the cable to the desired
length then attach the hook to the item being pulled. At this time, confirm the hook’s
spring-loaded latch is set.
NOTE: Leave at least 5 turns of the cable on the drum always. Read
over Winch safety warnings & precautions before continuing.
3. To pull another object, re-engage the clutch by turning the Clutch Knob until it is
secure in the IN position.
To avoid damaging the vehicle transmission, do not have the
transmission in park or in any gear. Make sure to set the
emergency brake and place wheel chocks, then put in neutral.
4. While standing along the tow path, press & hold the IN pushbutton on the
Remote Control to pull the load. If the load does not move, release pull switch and
confirm whether any obstacles are blocking the load from moving or if load is too
heavy to move. Now, press and hold the OUT pushbutton to release the load.
Before reversing directions, make sure motor stops.
5. After pulling, secure the load so that it does not move in either direction.
This utility winch is designed for intermittent use only and
should not be used in a constant duty application. The duration
of the winching job should be kept as short as possible. If the
winch motor becomes too hot, stop the winch and let it cool off.
Never pull for more than one minute, at or near the rated load.
Do not maintain power to the winch if the motor stalls as it can
damage the winch.
Maintenance
Lubrication
A.) No internal lubrication is required as all moving parts inside the winch have been
lubricated using high temperature lithium grease at the factory. Lubricate cable
every so often using a light penetrating oil.
Cable Assembly Replacement (to be performed only by a qualified technician)
A.) Move the Clutch handle to the OUT position. Extend Cable Assembly to the
full length. Notice how the existing cable is connected to the inside of the drum.
Remove the old cable assembly and secure the new one. Retract cable onto
cable drum being careful not to allow kinking.
4

Maintenance (Continued)
Always replace with approved replacement parts from Mile Marker.
Never replace with inferior parts.
General
1. Keep vehicle battery in good condition. Make sure winch battery cables are not drawn
taunt against any surfaces which could possibly damage them.
2. Corrosion will reduce performance or may cause a short circuit. Make sure to remove
and clean cable connections to the battery fuse box and chassis ground periodically.
Cover cables and winch when not in use.
Troubleshooting Instruction Insert
SYMPTOM
POSSIBLECAUSE
SUGGESTEDREMEDY
-SwitchAssynotconnected
properly Insert SwitchAssyfirmlytotheconnector.
-Loosebatterycable
connection
Tightennutsoncableconnectors
-Solenoidmalfunctioning Tapsolenoidtofreecontact,applying12volts tocoil terminaldirectly. Itwillmakean
audibleclickingwhenactivating.
-DefectiveSwitchAssy ReplaceSwitchAssy.
-Defectivemotor Checkforvoltageat armatureportwithswitch
pressed. Ifvoltageispresent,replacemotor.
Motordoes
notturnon
-Waterhasenteredmotor Drainanddry. Runinshort burstswithout
loaduntilcompletelydry.
Motorrunstoohot -Longperiodofoperation Letwinchcooldownperiodically.
-Batteryrunsdown Rechargebatterybyrunningvehicleengine.
Motorrunsslowlyor
withoutnormal power
-Insufficientcurrent or
voltage
Clean,tightenorreplacetheconnector.
Motorrunsbut cable
drumdoesnotturn -Clutchnotengaged TurnClutchGeartoIN/ENGAGEDposition.If
thatdoesnotwork,askaqualified
techniciantocheckandrepair.
-Defectiveorstucksolenoid Tapsolenoidtofreecontacts. Repairor
replacesolenoid.
Motorrunsinone
directiononly
-DefectiveSwitchAssy
ReplaceSwitchAssy
5

Winch Assembly and Parts Breakdown
PE 2000 (76-50100)
ITEM QTY PART # DESCRIPTION ITEM QTY PART # DESCRIPTION
1 1 76-50100-01 Motor End Bearing Assy. 14 4 76-50100-14 Screw M5 x 12
2
1
76-50110-02
Gear ring
15
2
76-50110-15
Screw M5 x 12
3
1
76-50100-03
Switch Assy.
16
1
76-50100-16
Mounting Frame
4
1
76-50110-04
Gear Carrier Assy.
17
1
76-50110-17
Small Bushing (Drum Support)
5
2
76-50110-05
Bushing
18
2
76-50100-18
Screw M6 x 16
6 1 76-50110-06 Dish Gear 19 3 76-50110-30 Bolt (M8x30), Nut (M8), Washer (8),
Spring Washer (8)
7 2 76-50110-07 Nut M 5 20 1 76-50100-20 Drum
8
1
76-50110-24
Clutch Knob
21
1
76-50100-21
Cable Assy.with Hook 50ft x 5/32"
9
1
76-50100-09
Tension Plate
22
1
76-50110-28
Hand Saving Belt
10
1
76-50110-22
Spring Pin D 2.5 x 10
11
1
76-50100-11
Bush
12
1
76-50100-12
Gear Box Cover
***When ordering parts from this list, make sure to indicate the exact part
number for your replacement and that it is from the Winch Parts List***
13
4
76-50110-13
Spring Washer D5
6

MILE MARKER, INC.
LIMITED 2 YEAR WARRANTY ELECTRIC WINCH
Mile Marker, Inc. offers a limited two (2) year warranty (to the original retail purchaser) for
each new Mile Marker consumer/RV electric winch against manufacturing defects in
workmanship and materials on all the mechanical components.
Electrical components consisting of motors, solenoids, wiring, wire connectors and associated parts
have a limited one (1) year warranty.
New cable assemblies are warranted against defects in workmanship and materials when received
by the retail purchaser. There is no applicable warranty after initial use.
Warranty registration cards for each winch must be submitted at the time of purchase or
within 30 days by the end user. Warranty will only be valid for the original purchaser of the
winch and installed on the vehicle for which it was originally registered.
Mile Marker electric winches are intended for recreational self-recovery usage. The
warranty is void if the winch is used in commercial/industrial applications.
The obligation under this warranty, statutory or otherwise, is limited to the replacement or
repair at the manufacturer's factory, or at a point designated by the manufacturer, of such
part(s) as shall appear to the manufacturer, upon inspection of such part(s) as shall appear
to the manufacturer, upon inspection of such part(s), to have been defective in material or
workmanship. This warranty does not obligate Mile Marker, Inc. to bear the cost of labor or
transportation charges in connection with the replacement or repair of defective parts, nor
shall it apply to a product upon which repairs or alterations have been made, unless
authorized by the manufacturer, or for equipment misused, neglected or improperly
installed.
IMPORTANT NOTICE:
To the fullest extent permitted by applicable law, the following are hereby excluded
and disclaimed:
All warranties of fitness for a particular purpose;
All warranties of merchantability;
All claims for consequential or incidental damages.
There are no warranties that extend beyond the description that appears on
the face hereof.
Some states do not allow the above exclusions or disclaimers in consumer transactions
and as such this disclaimer/exclusion may not apply to you.
To the extent such warranties of fitness or merchantability are deemed to apply to this
product, they exist for only so long as the express limited warranty elsewhere set forth is in
existence.
Mile Marker, Inc. reserves the right to change, alter or improve its products in design,
materials or appearance without incurring any obligation to incorporate such changes in
products that were previously manufactured.
This Warranty gives you specific legal rights and you may have other legal rights, which
vary from state to state. To submit a warranty claim contact:
MILE MARKER, INC.
WARRANTY ADMINISTRATOR
2121 BLOUNT ROAD
POMPANO BEACH, FL 33069 USA
PHONE: [phone]
LOCAL PHONE: [phone]
FAX: [phone]

2121 Blount Road Pompano Beach, FL 33069 USA
Phone [phone] [phone] Fax [phone] Email: [email protected]
What factors most influenced the purchase of your Mile Marker product? (Check all that apply)

Mile Marker reputation  Price

Availability  Warranty

Previous experience with Mile Marker Inc.  Internet

Friend/Relative recommendation  Advertising

Quality/Durability  Compatibility with vehicle

Salesperson’s recommendation
Salesperson Name: ___________________
First Name:
Last Name:
Age:
Sex:
Marital Status:
Level of Education:
City/Province:
Zip/Postal Code:
Country:
Telephone Number:
Email Address:
Which Mile Marker winch did you purchase?
Model Number:
Serial Number:
Date of Purchase:
Where did you purchase this product?
Store or catalog name:
Store location:
How satisfied were you with the
dealer and/or sales staff?
Who installed or will install
your Mile Marker product?
Is this the first time you
have purchased a winch?
If no, what brand have you
bought before?
Pickup:
Year: Make: Model:
What type of vehicle will this Mile Marker
winch be installed on?
Is this vehicle two or four wheel drive?
What is the vehicles main use?
What other accessories have you
purchased for your vehicle?
Do you belong to any 4-Wheel drive club? Yes or No If so, what is the Club name:
8