Overland Vehicle Systems SCAR User manual

SCAR Winch
INSTRUCTIONS
CAREFULLY READ INSTRUCTIONS PRIOR TO
THE FIRST USE OF THE WINCH
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SCAR Winch
SET-UP & CARE INSTRUCTIONS
19129901 – 12,000 LB SCAR WINCH SYNTHETIC ROPE
19119901 – 12,000 LB SCAR WINCH STEEL CABLE
19099901 – 10,000 LB SCAR WINCH SYNTHETIC ROPE
19089901 – 10,000 LB SCAR WINCH STEEL CABLE
GET TO KNOW YOUR WINCH
We recommend you check all parts are included prior to rst use.
TABLE OF CONTENTS
Each SCAR Winch Includes:
10,000 LB or 12,000 LB Winch Assembly
Hawse or Roller Fairlead

Forged Winch Hook

Item Page
 3
 5
 4
 5
Winch Maintenance 10
 12
Parts List 14
 15
Warranty 16
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SCAR Winch
SET-UP & CARE INSTRUCTIONS
19129901 – 12,000 LB SCAR WINCH SYNTHETIC ROPE
19119901 – 12,000 LB SCAR WINCH STEEL CABLE
19099901 – 10,000 LB SCAR WINCH SYNTHETIC ROPE
19089901 – 10,000 LB SCAR WINCH STEEL CABLE
3
VERSION 001- 7.10.23






Do not operate or stand next to an operang winch wearing loose clothing or jewelry. Loose items can get
caught in moving parts of the winch during operaon.
Always wear protecve gloves when operang the winch. Leather gloves are recommended. Do not operate
the winch or handle the winch cable with bare hands. Winch components can get hot and winch cable can
have brokewires.
Always wear closed toe shoes when operang the winch. It is highly recommended to wear
non skid footwear.

Ensure that all people stand clear of the winch and winch cable during operaon. It is recommended that
during winch operaon bystanders are standing at least 1.5 mes the winch cable length. If the winch cable
were to come loose or break under load, it can snap back and cause serious injury and/or death.
Do not stand in front of the winch during operaon. All bystanders should be kept away from the work area
and operang winch.
Never step over the winch cable
Keep proper foong and balance and always be mindful of the winch line.
Handle Winch Remote with Care
Note that the winch remote is not IP68 rated. It should be stored securely inside the vehicle away from any
moisture when not in use. Over exposure to moisture can lead to damage or failure to the remote.
When using the winch remote wire lead, ensure proper alignment of the pin and socket at the control box.
Inspect both connecons before each operaon. Damaged pins can cause winch failure.
READ
INSTRUCTIONS
WEAR
GLOVES
PULL TAB
FROM HOOK
KEEP AWAY
WHILE OPERATING
DO NOT USE WINCH
IN OVERWIND



DONT STAND
IN FRONT OF
WINCH WHILE
OPERATING


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SCAR Winch
SET-UP & CARE INSTRUCTIONS
19129901 – 12,000 LB SCAR WINCH SYNTHETIC ROPE
19119901 – 12,000 LB SCAR WINCH STEEL CABLE
19099901 – 10,000 LB SCAR WINCH SYNTHETIC ROPE
19089901 – 10,000 LB SCAR WINCH STEEL CABLE
4
VERSION 001- 7.10.23
Do not yank the cord to disconnect it from the receptacle.
The remote must be kept free of dirt and moisture to ensure safe operaon.
Keep both remote and remote wire lead away from heat, moisture, oil and sharp edges.

During operaon, if the motor becomes uncomfortable to touch during heat, stop operaon and allow the
winch to cool for a few minutes.
If the winch stalls during operaon, DO NOT maintain power to the winch. Turn o at the control box and
allow the winch to cool before resuming operaon.
NEVER exceed the maximum line pull rangs. Shock loads must always be avoided.
For loads over ½ of the rated capacity, it is recommended to use a snatch block or double line arrangement.

Winch power switch on the control box should be on the o posion when not in use.
Clutch handle should be in the disengaged or free spool posion and the winch line hook should be secured
when not in use.
Prior to use, make sure that the clutch handle is fully engaged.

Before each use, carefully check all components before operang. Do not use if any component appears
to be damaged.
Any damaged part should be properly repaired or replaced prior to connued use.
When repairing or replacing damaged parts, only use idencal replacement parts provided by the
manufacturer to prevent the risk of damage or potenal danger to the user.

Protecve gloves such as leather gloves must be worn when handling the winch line. To re-spool correctly, a
slight load on the line is necessary. Refer to re-spooling direcons in the operaon manual.
Avoid allowing the winch line to slide through your hand and never allow hands or loose clothing too close to
the moving parts of the winch or winch line.
Power the winch line in unl there is approximately 3 feet of winch line remaining.
If using winch power to fully re spool the line, Keep hands clear
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SCAR Winch
SET-UP & CARE INSTRUCTIONS
19129901 – 12,000 LB SCAR WINCH SYNTHETIC ROPE
19119901 – 12,000 LB SCAR WINCH STEEL CABLE
19099901 – 10,000 LB SCAR WINCH SYNTHETIC ROPE
19089901 – 10,000 LB SCAR WINCH STEEL CABLE
5
VERSION 001- 7.10.23




Store the remote control and control lead inside your vehicle where it will not become damaged or exposed to
the elements. Inspect the controller, lead and connecon before you plug it in.
Be sure the winch line is in good condion. Do not use winch if line shows signs of wear (frayed, cut or torn for
example).
Never move the vehicle to assist pull a load using the winch line. This can overload the winch or cause a
damaging shock load.
Avoid sudden loads on the winch. Shock loads can occur by vehicle movement placing a sudden load on
the winch line.
Never replace the cable line with a line of lesser strength.
If replacing the line, make sure to use Locte or similar compound to the clamp to secure the line to the drum.
When respooling, make sure there is at least 500lbs of load on the line. The load will allow a proper and ght
wind on the drum prevenng the outer layers of line to draw into the inner layers potenally causing damage
to the line.
When pulling a load in, monitor how the line is spooling on the drum. Try to avoid uneven spooling. To do so,
reverse the line to relieve the load and try to anchor to a point that is more center to the winch. If slight
uneven spooling occurs, once the pulling task is complete, take the me to properly and neatly respool the line.
Slight uneven spooling while under load is ok but watch for bunching of the line on one end or the other of the
drum and clearance of the line and the winch housing.
Monitor the winch while in use. Stand at a safe distance. Stop winching every 3-4 feet and inspect the line is
not piling up. Uneven piling of the line can jam the line and winch potenally leading to a failure.
Avoid winch line binding. Binding can occur when winching in under load and the line is pinched between the
others. If binding occurs, alternate powering in and out. Do not aempt to unbind the line while under load.
When ready to operate and winch a load in, prior to plugging in the winch remote, make sure the winch clutch
handle is in the free spool or disengaged posion. Do not aempt to engage the clutch while the winch motor
is running.
DO NOT connect the winch line hook back to the winch line. This will damage the line. Always use properly
rated recovery accessories to properly anchor or secure the line.
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SCAR Winch
SET-UP & CARE INSTRUCTIONS
19129901 – 12,000 LB SCAR WINCH SYNTHETIC ROPE
19119901 – 12,000 LB SCAR WINCH STEEL CABLE
19099901 – 10,000 LB SCAR WINCH SYNTHETIC ROPE
19089901 – 10,000 LB SCAR WINCH STEEL CABLE
6
VERSION 001- 7.10.23
If using a vehicle tow hook, make sure it is frame mounted and rated as a recovery point. Do not secure a
tow hook to the winch mounng plate.
Ensure all other recovery items used in conjuncon with the winch have adequate load rangs.
When using a snatch block or other pully conguraon during staonary winching, the winch hook should be
aached to the chassis of the vehicle.
When winching, always maintain a minimum or 5 wraps for steel cable and 10 wraps of synthec line around
the drum. Failure to do so can result in the line parng with the drum under load and can cause serious
personal injury and property damage.
When pulling heavy loads, it is recommended to use a snatch block or double line arrangement.
Always use a weighted winch dampener or heavy blanket draped over the winch line. It will help dampen back
lash in the result of a cable or line failure.
Be sure that the baery is in good condion and always wear eye protecon around the baery.
When using the winch, have the vehicle running to provide consistent power and avoid draining the baery.
DO NOT use the winch for hoisng applicaons.
DO NOT use the winch to support, li or move personnel.
DO NOT exceed the pulling limits of the winch.
DO NOT rotate clutch handle to free spool when there is a load on the winch line.
The winches described in this manual were designed and intended for vehicle self-recovery and are not
intended for industrial use.

Warning: The installaon of winches and/or a winch suitable bumper or carrier may aect the triggering of SRS
airbags. Check that the mounng system has been tested and approved for winch tment in the
airbag-equipped vehicle. Failure to comply may cause death or severe personal injury.
The winch is to be mounted into a suitable steel mounng frame using the 4-pont foot mounng system either
a horizontal or vercal plane. It is very important that the winch be mounted on a at surface so that the three
secons (motor, cable drum and gear housing) are properly aligned.
The winch should be secured to the mounng with the included bolts and washers provided. The winch plate
must be at least 6mm thick. Thicker winch plates may require longer bolts (not included). Ensure winch
mounng bolts protrude past the top surface of the square nut for proper thread engagement.If longer
hardware is needed to mount to your specic locaon, replacement hardware must be grade 8.8 or greater.
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SCAR Winch
SET-UP & CARE INSTRUCTIONS
19129901 – 12,000 LB SCAR WINCH SYNTHETIC ROPE
19119901 – 12,000 LB SCAR WINCH STEEL CABLE
19099901 – 10,000 LB SCAR WINCH SYNTHETIC ROPE
19089901 – 10,000 LB SCAR WINCH STEEL CABLE
7
VERSION 001- 7.10.23
The roller or hawse fairlead is to be mounted to guide the rope onto the drum evenly.
Improper use, inadequate fairlead to bumper clearances, abuse, neglect, and chang damage are not covered
by any warranty.


Installaon Instrucons

The SCAR control box was designed to be mounted center over the drum using the provided 4 hex bolts
ghtening with the provided hex key.
If your applicaon calls for more clearance, the control box can be oset and mounted over the motor
using 2 of the provided hex bolts. This orientaon will provide addional clearance for power wires when
mounng the winch close to a grille.
Winch Clocking
The SCAR Winch can be clocked on the gearbox side for easier clutch handle access for certain mounng
soluons. WARNING: Improper reassembly of the winch can aect its funcon and waterproofness. Take
great care and ensure that the gasket is not damaged and is properly in place upon reassembly.
Disconnect the winch from the power supply.
Rotate the clutch handle to the free spool posion.
Secure the winch upright on the motor end.
Remove the 7 hex head bolts and lock washers securing the control box.
Using even pressure, carefully slightly li up the gear box making sure to keep the gasket seated on the
winch itself.
Rotate the gear box to the desired orientaon. Note, the clocking must be in 90 degree increments.
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SCAR Winch
SET-UP & CARE INSTRUCTIONS
19129901 – 12,000 LB SCAR WINCH SYNTHETIC ROPE
19119901 – 12,000 LB SCAR WINCH STEEL CABLE
19099901 – 10,000 LB SCAR WINCH SYNTHETIC ROPE
19089901 – 10,000 LB SCAR WINCH STEEL CABLE
8
VERSION 001- 7.10.23
When seang the gear box ensure that the gasket is properly aligned and seated in the machined groove.
If the gasket is ripped or damaged it must be replaced.
Once properly seated and aligned secure the gear box with the previously removed 7 hex head bolts ghtening
in a star paern making sure the gear case is properly seated.
Place the winch down and rotate the clutch lever to ensure that the winch drum operates correctly in the free
spool and engaged posions.

WARNING: Baeries contain gasses which are ammable and explosive. Wear eye protecon during
installaon and remove all metal jewelry. DO NOT lean over baery while making connecons.
For normal self-recovery usage, a normal vehicle electrical system is adequate. The operang baery must
be in good working condion and is essenal to the proper funcon of the winch. Always have the operang
vehicle running during all winch operaons to provide constant power and prevent the baery from draining
during use.
Pay close aenon to proper cable connecon and make sure that all wires are free from crimping or
potenal abrasion.




Winch_Instructions_Final.indd 8Winch_Instructions_Final.indd 8 7/10/23 8:23 PM7/10/23 8:23 PM

SHORT BLACK CABLE WITH YELLOW HEAT SHRINK SHORT BLACK CABLE WITH RED HEAT SHRINK SHORT BLACK CABLE WITH RED HEAT SHRINK
THIN SHORT BLACK CABLE GROUND
TERMINAL BLUE
TERMINAL RED
TERMINAL YELLOW
LONG BLACK CABLE W. RED SHRINK
      
Winch_Instructions_Final.indd 9Winch_Instructions_Final.indd 9 7/10/23 8:23 PM7/10/23 8:23 PM

SCAR Winch
SET-UP & CARE INSTRUCTIONS
19129901 – 12,000 LB SCAR WINCH SYNTHETIC ROPE
19119901 – 12,000 LB SCAR WINCH STEEL CABLE
19099901 – 10,000 LB SCAR WINCH SYNTHETIC ROPE
19089901 – 10,000 LB SCAR WINCH STEEL CABLE
10
VERSION 001- 7.10.23











Make sure that the vehicle with the winch properly mounted is secure by applying the parking break and
checking the wheels.
With the winch power o at the control box and the winch clutch in the free spool posion, pull out the winch
line to the desired length to connect to an anchor point.
You should always free spool the winch outward.
Once the line is properly secured to the anchor point, rotate the clutch handle to the engaged posion.
Recheck all rigging prior to operang the winch.
The remote is wireless but it is recommended to use the remote lead and connect directly to the control box
unless it is unsafe to do so.
Turn on the winch power at the control box then plug in the remote making sure that the pins and socket is
aligned. Take special care that the pins and socket are aligned not to damage the connectors.
Turn the remote power on
To start winching, start the vehicle then place it in neutral and maintain engine speed at idle.
Push the desired switch on the control to operate the winch line either in or out.
Operate the winch but regularly check the winch to make sure the line is winding around the drum evenly.
Connue this process unl the vehicle is retrieved.
Note:



Winch_Instructions_Final.indd 10Winch_Instructions_Final.indd 10 7/10/23 8:23 PM7/10/23 8:23 PM