Mile Marker HI9000 Setup guide

Installation and Operator’s Manual
HI9000 (PN 75-50085C) HI10500 (PN 75-50050C)
HI12000 (PN 75-52000C)
2121 BLOUNT ROAD
POMPANO BEACH, FL 33069 USA
WWW.MILEMARKER.COM
[email protected]OM
800.886.8647 TOLL FREE
954.782.0604 USA & INT’L
954.782.0770 FAX
HISERIES

Safety Warnings & Precautions ................................2
Winching Tips & Techniques.....................................4
Getting Started:
Unpacking Your Winch........................................6
Winch Mounting..................................................6
Attaching Valve Assembly..........................................7
Wiring Instructions....................................................8
Plumbing Connections ...............................................9
Winch Operation...................................................... 11
2-Speed Lever Positions..........................................12
Parts List ................................................................13
Warranty .................................................................14
TABLE OF CONTENTS
Page 1
2121 BLOUNT ROAD
POMPANO BEACH, FL 33069 USA
WWW.MILEMARKER.COM
[email protected]OM
800.886.8647 TOLL FREE
954.782.0604 USA & INT’L
954.782.0770 FAX

SAFETY WARNINGS
1. Wear leather gloves when handling winch cable. DO NOT handle cable with bare hands as broken wires can cause injuries.
2. When extending winch cable, ensure that at least five wraps of cable remain on drum under load. Serious personal injury or property damage
may result.
3. Ensure that all persons stand well clear of winch cable and load during winch operation, 1.5 times the cable length is recommended. If a
cable pulls loose or breaks under load it can lash back and cause serious personal injury or death.
4. Draping a heavy blanket or similar object over the extended winch cable is recommended as it will dampen any lash back should a
failure occur.
5. Ensure rated “D” or bow shackles are used in conjunction with an approved tree trunk protector to provide a safe anchor point.
6. DO NOT operate the winch control when the engine is OFF and a load remains on the cable. This may put the winch into freespool mode
when not required, therefore not holding the load.
7. Ensure the winch clutch is totally engaged before starting any winch operation. When engaging or disengaging the clutch it may be necessary
to rotate the drum by hand to align the clutch pin.
8. NEVER disengage the winch clutch under load.
9. Store the winch with clutch lever function in the HIGH GEAR position.
10. The maximum winch capacity is available on the first layer of rope on the bare winch drum. During all winching operations it is recommended
to unspool the rope back to the first layer so as to provide maximum capacity and avoid rope damage. Ensure that at least five wraps of
cable remain on the drum at all times.
11. The use of a snatch block will aid recovery operations by providing: A doubling of the winch capacity and a halving of the winching speed;
and the means to maintain a direct line pull to the center of the rollers.
12. The MileMarker winch is a 2-speed unit, low speed for vehicle recovery winching and high speed for line retrieval.
13. DO NOT use the winch to lift, support or otherwise transport personnel.
14. DO NOT drive your vehicle to assist the winch in any way. Vehicle movement in combination with winch operation may overload the cable,
the winch itself, or cause damaging shock loads.
15. Shock loads when winching are dangerous! A shock load occurs when an increased force is suddenly applied to the cable. A vehicle rolling
back on a slack cable may induce a damaging shock load.
Page 2

PRECAUTIONS
1. Keeps hands and body away from Fairlead (cable intake slot) when operating.
2. Secure vehicle in position before using winch.
3. Do not exceed winch load weight capacity (see Winch Specifications).
4. Be certain winch is properly bolted to a structure (or vehicle) that can hold the winch load.
5. Always use proper couplings when connecting winch cable hook to load.
6. Do not lift items vertically. The winch was designed for horizontal use only.
7. Do not overload the winch (see Model Specifications). It will do the job better at the load it was intended.
8. Do not use inappropriate attachments to extend the length of the winch cable.
9. NEVER LIFT PEOPLE OR HOIST LOADS OVER PEOPLE.
10. Never come in between the winch and the load when operating.
11. Do not apply load to winch when cable is fully extended. Keep at least 5 full turns of cable on the drum.
12. After moving an item with the winch, secure the item. Do not rely on the winch to hold it for an extended period.
13. Examine winch before using. Components may be affected by exposure to everyday weathering, chemicals, salts, and rust.
14. Never fully extend cable while under load. Keep 5 COMPLETE TURNS of cable around the winch drum.
15. When loading a boat into a trailer without reel or side hull rollers, make sure the trailer is submerged in the water when the boat is loaded by the
winch. Attempting to drag the boat on to the trailer while on land can cause winch failure and possible injury.
16. Never operate winch if cable shows any signs of weakening, is knotted or kinked.
17. Winch does not have a locking mechanism. Secure load after moving.
18. Do not cross over or under the cable while it is in process of loading.
19. Do not move vehicle with cable extended and attached to load to pull it. The cable could snap.
20. Apply blocks (such as a wheel choke) to vehicle when parked on an incline.
21. Re-spool cable properly.
Page 3

WINCHING TIPS & TECHNIQUES
Winching Tips and Use of a Snatch Block
•Use OEM tow hooks, recovery eyes or a clevis mount for attachment of a tow strap or winch cable. Warning: Never use a ball and/or ball
mount as an anchor point for tow strap or winch cable. Severe personal injury or death could occur.
•Always heed all winch manufacturer’s recommendations, cautions, and warnings.
•Attach return cable to tow hook or recovery eye when using a snatch block. Always use a clevis to secure snatch block to strap, or severe
damage could occur to persons and vehicle. (See Figure Below). Caution: Never attach return cable to winch mount. This may overload winch
mount and/or front receiver.
Rating
Safety Tips
For maximum line pull rating, winch cable direction must not exceed:
1. 15º angle up or down from horizontal (See Figure Below).
2. 45º angle left or right from straight ahead (See Figure Below).
Caution: Exceeding the maximum line pull rating may overload winch,
winch mount, and/or front mounted receiver.
•NEVER DISENGAGE CLUTCH LEVER WHEN THERE IS A LOAD ON THE WINCH. Mile Marker electric winches utilize an automatic load holding
brake, therefore no adjustment to clutch is needed to maintain load.
•Store the remote control cord in a safe place when not in use to prevent use by children or other unauthorized persons who could injure
themselves or others or damage the controls.
•Do not operate winch inder the influence of drugs, alcohol, or medications.
•Isolate winch before putting hands in or around the fairlead or wire rope drum (The Danger Zone).
•DO NOT OVERLOAD YOUR WINCH. Do not maintain power to the winch if the drum stops. Overloads can damage the vehicle, winch or winch
rope and create unstable operating conditions.
•It is recommended to lay a heavy blanket or jacket over the rope about halfway along to the hook attachment. If a rope failure should occur,
the weight of the cloth will act as a damper and help prevent the broken rope from whipping (See Figure Below). Remember to move the
blanket or jacket as winching proceeds, but halt winching when doing so. Partially raising the hood of the vehicle will also give a measure of
protection to its occupants from broken rope or cable, consistent with sufficient forward visibility for the operator.
Page 4

Self Recovery
Use of a Pulley Block or Snatch Block
Use of a Nylon Sling and Shackle
Use of Gloves
1. Always attempt to get the cable as straight as possible to the direction of the vehicle. It is acceptable to start a pull at an angle if it is obvious
that the vehicle will turn towards the hook anchoring point. Turning the steering wheel will assist the process. It is recommended that the
driver is in the vehicle.
2. Make sure hand brake and foot brake are free and that the transmission is in neutral.
3. When the driver’s attempt to regain vehicle traction is successful, he or she should be careful not to overrun the cable and risk the possibility
of it being trapped under the vehicle.
4. DO NOT move your vehicle in reverse to assist the winch. The combination of the winch and vehicle pulling together could overload the cable
and winch itself.
Vehicle self-recovery using the pulley block attached to the anchor point for direct pull. In this instance the vehicle becomes the “load” and the
actual pulling power on the vehicle will be double at half winch rope speed. Never connect wire rope or hook back to winch mount!
A shackle should always be used when attaching winch hooks to nylon slings. NOTE: The shackle must pass through both eyes of the sling.
The safe working load of the nylon sling is based on the use of both eye ends. Never use the cable or hook to connect directly to the nylon sling.
When handling or rewinding the cable always use gloves to eliminate the possibility of cuts caused by burrs and broken strands. Inspect cable and
equipment frequently. The cable should be replaced immediately if any sign of burrs or broken strands are evident. A frayed cable with broken strands
should be replaced immediately. Always replace the cable with a Mile Marker recommended replacement part. Any substitution must be IDENTICAL in
strength, quality, lay and stranding. Never hook the cable back onto itself. Hooking the cable back onto itself creates an unacceptable strain, breaking
individual strands which in turn weakens the entire cable. Use a sling. Avoid continuous pulls from extreme angles as this causes cable to pile up at one
end of the drum.
Below: Direct pull on load using the winch vehicles as the anchor with pulley block attached to the load. The most important aid to successful
winching (after the winch) is the pulley block, which can be used to increase the pulling power of the winch of for indirect pulls. Pulley blocks
can be used in two modes. First mode is attached to the load and second is secured to an anchor point.
Below: Indirect pull necessitated by obstructions or soft ground. Pulley block attached to load using a suitable anchor point. Note the angled
direction taken by the load and subsequent angle of rope feed-back on the winch drum (extreme example shown). There may be unavoidable
circumstances requiring this mode, though in general it is not recommended unless applied in stages by moving the anchor point or vehicle
to avoid the sharp angled rewind on the winch drum. The actual load pulling power and rope speed will depreciate with any increased angle
between the ropes. The anchor point, when used must be secure, using a tree, another vehicle or any firm structure to which a pulley block
can be used to your advantage.
Page 5

GETTING STARTED
Unpacking Your Winch
Typical Installation
Unpack your new Mile Marker winch and ensure that all the parts are included by referring to parts list and exploded view drawings provided in this manual.
Depending on amount of clearance between winch mount tray and winch body, attach the roller fairlead with two bolts (B-3/8 16 X 1¼ SS Hex Head Bolt) through
roller fairlead and pre-drilled holes on front of winch mount tray and attach with 3/8 SS nuts (not provided) . When facing grill of truck, position the winch with the hydraulic
2-speed levers to the left (passenger side). The Free/Low lever will be on top. In this position, 4 mounting holes will be on the bottom on any style of Mile Marker winch.
Attach winch to winch-mount tray by screwing 4 bolts (C-3/8 X 16 X 1 SS Hex Head Bolt) and washers (D-3/8 SS Washer) through the pre-drilled holes in bottom
of winch mount tray into bottom of winch body. Tighten to 35 ft/lbs. Make sure that you have AT LEAST 6 threads going into the winch legs, but NO MORE THAN
10 threads going into winch leg.
NOTE: If you find any missing or broken parts, please call Mile Marker as soon as possible at the number present on the front page of this manual.
Winch Mounting
Your winch should be aligned and secured to a solid part of the vehicle (front or rear) where the full rated load will be evenly distributed.
NOTE: Mile Marker recommends the use of its mounting systems for proper winch installation and optimum winch performance. However, when
not using Mile Marker Mounting System, ensure that the mounting platform is strong enough to meet the maximum rated load of the winch in use.
Mile Marker recommends steel plates with thickness of at least 0.25”.
CAUTION: It is essential that the mounting surface be flat and the winch is mounted such that the three major sections (Gear housing end,
drum and motor end) are in proper alignment.
CAUTION: When replacing the capscrews or when longer bolts are required, make sure that you use bolts of Grade 5 or greater.
Winch body on 9000 lb. and 10500 lb. winch has mounting holes only on the bottom. Winch body on 12000 lb. winch has four mounting holes
on front, back, and bottom of the winch. This may allow the winch to be mounted easier on some winch mounts or for other applications.
The motor on Mile Marker 2-speed winches may also be rotated in 90º increments if needed. This may allow easier installation on somewinch mounts.
Page 6
CABLE MUST SPOOL OFF THE BOTTOM OF THE DRUM

ATTACHING VALVE ASSEMBLY
Rotate winch onto its front so that smooth machined area on the winch motor is facing up.
Remove rubber plugs from holes in the side of the winch motor. Remove the 2 Motor square-cut 0-rings from rubber plugs and re-seat at the lips
of the holes from which they were removed in the motor.
Remove rubber bands from valve assembly being sure not to drop metal washers (B) and flow disk (C).
The purpose of the flow disk is to maintain back pressure for controlled release of cable under tension. If this disk is installed improperly it will
negatively affect the performance of your winch and greatly reduce its pulling power. This is a safety item; IT MUST BE INSTALLED.
BEFORE SECURING VALVE ASSEMBLY TO THE MOTOR MAKE SURE THAT THE FLOW RESTRICTOR DISK IS IN PORT LABELED #1 WITH
THE FLAT SIDE FACING THE SOLENOID BODY AND THE CUT SIDE FACING THE WINCH MOTOR. Also, make sure that the hole(s) in the valve
assembly have thin O-ring(s) installed, then re-seat the metal washer(s).
Use the four allen bolts supplied (f-5/16 18 X 1 ½ SS Socket Head Cap Screw) to mount the solenoid valve to the winch motor. Make sure to
Lock-Tite the allen bolts using no washers. Tighten to 25 ft/lbs.
NOTE: A small dab of axle grease can be used to help hold the metal washers in place.
NOTE: Lock-Tite not included.
Page 7
Figure 1
Used on 9,000 lb - 10,500 lb Winches Used on 12,000 lb Winches

Page 8
WIRING INSTRUCTIONS
Electrical Connections
The power source to the solenoid can not be energized until the four-pole quick connector plug is plugged in. Each solenoid has two black wires
that are connected to each other at the factory and are grounded. The other black wires will plug into the white and black wires from the hand
control connection shown in figure 4. The brown wire will go to ground from the female 4 pole plug gray box. Attach the circuit breaker to the
vehicle under the hood. Connect all wiring as shown in illustration. Test hand control unit, solenoids will make a slight “click” sound if connected
correctly. Do not start vehicle to do this test.
When done, check fluid level. Replace lost fluid in system until full. To purge air, start engine, run for two seconds and shut off engine. Check
fluid level again. Add fluid until full. Do this until system stays full. Run truck for three minutes or until fluid looses aeration. After system has
been filled, turn wheels from lock to lock position (completely right and left) five times. This will aid in bleeding out any air that may still be in
the system. If the hand control unit is working backwards, simply reverse the connections at the solenoids (switch the white and black wire on
the solenoid valve). See Figure 4. Make sure that you hear a slight “hiss” when the hand controller is pressed “out” when the vehicle is running.
DO NOT CONNECT POWER CABLES TO BATTERY UNTIL FINAL STEP OF INSTALLATION!
Figure 3
CAUTION: Winch cable must be wound onto the drum under a load of at least 500 lbs or outer wraps will draw into the inner wraps and
damage the winch cable.

Page 9
PLUMBING CONNECTIONS
Keep all hoses away from any areas where heat may be considered too extreme (such as exhaust manifold or turbo). Lines cannot be mounted
or allowed to rub on any abrasive or vibrating/moving surfaces
Installation Procedures
1. REMOVAL OF FACTORY HOSE: Take a clean drain bucket to catch the oil and place under the vehicle.
2. VACUUM BRAKES (NON HYDROBOOST): If the vehicle is NOT equipped with hydroboost, remove the factory high pressure hose from the
power steering pump to the steering box. Let it drip dry, and store in safe place. This will be necessary to re-install if the winch is ever removed
from vehicle. See Figure 2..
3. HYDROBOOSTED: If the vehicle is equipped with hydroboost, remove the factory high pressure hose from the hydroboost to the steering box.
There is only one high pressure hose going to the steering box. See Figure 3.
4. NOT SURE?: Which one is the high pressure hose? The hose with heavy duty crimped on fittings. The low pressure return lines from the
steering box or hydroboost both end up at the pump reservoir will have hose clamps or something similar.
Does the factory hose have a sensor in it? What this does is increase the rpm of the engine slightly when there is high power steering pump
pressure during idle. We have found this is not needed. Remove it from the factory hose and install it back into the wiring harness plug. Tape it
securely in place. The vehicles computer will not be affected.
5. INSTALL THE ADAPTERS: Take the MM adapter kit for the vehicle; match the fittings up to those on the factory hose you removed. Re-use
the factory “O” rings; install them on MM fittings if required. There may be more than two fittings in the kit due to multiple applications. You
will only need two of them. Install them and tighten to the factory specifications. Take the solenoid fittings (“M”/90-50067 and “O”/90-50091)
place into the “P” and “T” ports of the black solenoid valve block. You will have to look and see where they will best suit your application in
mating up with the hoses from the engine bay. Then add the 90 degree “N”/90-50060 fitting to the straight fitting “O”/90-50091 you just in-
stalled. Remember the hoses will come thru either the grill or under the truck in an open area. When you are sure of where the fittings will face,
tighten them in place making sure the “O” ring is compressed (tight) or for the flare fitting, ¼ turn past finger tight.
Figure 2

6. CONNECTING THE HOSES: There will be two JIC -6 hoses provided in the kit. One is “S”/60” and the other is “T”/78”. Connect the 78” hose
from the power steering pump or hydroboost to the “P” port on the black solenoid block. Connect the 60” hose from the “T” port of the black
solenoid block to the steering box. These can go thru the grill of the truck or under the radiator area. Tighten the flare fittings hand tight then
go ¼ turn more. They can be longer than needed sometimes as this is designed to fit many applications. For that custom look, the local
hydraulic shop can shorten them or call us, we can also do it.
For pictures:
SEE FIGURE 2 for vacuum brakes
SEE FIGURE 3 for hydroboost brakes
CAUTION: DO NOT OVER TIGHTEN FLARE FITTINGS. They will crack and then leak. The only way to fix them will be to replace them.
Figure 3
Page 10

WINCH OPERATION
General
General
Unwinding Winch Cable
Pulling Load
Operation of High Gear
Preparation for Use
The vehicle’s steering pump is used to power the winch. The engine must be running while operating the winch, as the engine turns the power
steering pump which pumps fluid to rotate the winch. The winch will have full pulling capabilities at an engine idle. The winch is operated by an
electric activated switching valve. When engaging or disengaging the clutch and/or shift lever, it may be necessary to rotate the drum by hand
to align gears.
The vehicle’s steering pump is used to power the winch. The engine must be running while operating the winch, as the engine turns the power
steering pump which pumps fluid to rotate the winch. The winch will have full pulling capabilities at an engine idle. The winch is operated by an
electric activated switching valve. When engaging or disengaging the clutch and/or shift lever, it may be necessary to rotate the drum by hand
to align gears.
To unwind cable by hand, turn top lever to “FREE” (free spool). Turn side lever to “FREE” (free spool). Both levers should be in “FREE” positions
to unwind cable.
Turn top lever to “LOW” (lock low gear). Leave the side lever at “FREE” (free spool). This will engage the winch into low gear.
Turn top lever to “FREE.” Turn side lever to “HIGH” (lock high gear).
Operate remote control switch to “IN” or “OUT” until load has been retrieved. Secure winch after operation.
1. For use in pulling objects other than self recovery, park vehicle directly facing object to be winched. Apply parking brake.
2. Place transmission shift lever in “N” (neutral).
3. Start engine.
4. Chock wheels.
CAUTION: Wear leather gloves when handling winch cable. Do not handle cable with bare hands. Broken wires cause injuries. When fully
extending winch cable, make sure that five wraps of winch cable remain on drum at all times. Failure to do this may cause serious injury. Pull off
cable by hand to desired length. Connect to load leaving one foot of slack in cable.
CAUTION: Direct all personnel to stand clear of winch cable during winch operation. A snapped winch cable will cause serious injury or death.
Do not activate winch electric connector when engine is OFF with a LOAD on cable. This can put the winch into a retarded free spool mode.
CAUTION: Direct all personnel to stand clear of winch cable during winch operation. A snapped winch cable will cause serious injury or death.
Do not activate winch electric connector when engine is OFF with a LOAD on cable. This can put the winch into a retarded free spool mode.
Page 11

2-SPEED WINCH LEVER POSITIONS
Page 12

PARTS BREAKDOWN
Page 13

WARANTY INFORMATION
Hydraulic Winch Limited Warranty
Mile Marker Industries warrants each winch when used in normal service against factory defects in materials and workmanship to the original purchaser, (Commercial and Recre-
ational Warranty) for the period of two (2) years. (Exclusion from this warranty are cables, the finish, and any condition Mile Marker determines to have been caused by misuse,
abnormal use.) The Mile Marker hydraulic motor has a five (5) year warranty. The owner will be responsible for removing the winch and returning it to Mile Marker freight prepaid.
Mile Marker will repair or replace any or all winch parts it determines to be defective after inspection. See each individual product package for more detailed warranty information.
FOR FULL WARRANTY, PLEASE REGISTER YOUR PRODUCT ON OUR WEBSITE AT
WWW.MILEMARKER.COM/WARRANTY
Page 14

2121 BLOUNT ROAD
POMPANO BEACH, FL 33069 USA
WWW.MILEMARKER.COM
[email protected]OM
800.886.8647 TOLL FREE
954.782.0604 USA & INT’L
954.782.0770 FAX