POWERWINCH 316 User manual

#3910=0M
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OWNER'S MANUAL
Electric Winch - 12 Volt
Models 316, VR-192

-- READ ENTIRE INSTRUCTIONS BEFORE STARTING
INSTALLATION. FOLLOW ALL CAUTIONS, WARNINGS
AND NOTES TO PREVENT INJURY OR DAMAGE
TO WINCH, OR TO SELF.
A. Read your Owner's Manual. Only let
people whohave read and understandthe
Powerwinch safety rules use your winch.
B. NEVER useyourwinchto liftormove
peopleor animals..
C. DO NOT USE YOUR WINCH AS A
HOIST! It is not made to be used for verti-
cal lifting.
D. KEEP the winching area FREE OF
CHILDREN! ONLY let adults use your
winch.
E. ALWAYS wire your winch with the circuit
breaker. This Is your assurance against
overheating and fire potential.
F. ALWAYS stand clear of the area between
the load or anchoring point, and your
winch. Should the cable snap while you
are in this area you could be seriously hurt.
G. ALWAYSInspect the entirecablebefore
useto check for fraying or kinking.The
cable couldbreak if it is frayed (wornby
rubbing)or kinked(short,tighttwistsor
cuds).
H. If you are using the emergency hand
crank, BE SURE to remove it from the
winch after use. Under power the crank will
turn end could cause an injury.
It,.
L
M.
N.
O.
If you need to replace the cable, ALWAYS
replace it with one of the same size and
strength. Use Powerwinch cable only!! The
winch rating and cable strength are care-
fully matched. Your warranty is void if any
other cable is used.
Never use rope instead of cable. Your
winch under load has the force to snap
rope easily--causing possible damage.
ONLY attempt to pull as much as your
winch is rated for.
NEVER wrap the winch cable around the
load. This causes cable kinking, which
breaks down cable strength. Use an Eco-
Strap or chain.
DO NOT USE your winch to secure aload
for traveling or to hold or support a load
once you finish the job. It is not meant to
be used this way. ALWAYS secure the
load properly! If you do not you risk injury,
damage or loss of the load.
ALWAYS wear leather gloves when
handling the cable. Steel cable can be
hard on the hands.
ALWAYS keep your hands and feet clear of
the drum area (where the cable winds on
spool).
-"- i mr
WARNING: ALWAYS UNPLUG THE WIRING HARNESS TO PREVENT ACCIDENTAL
STARTING WHEN SE-nING UP, ADJUSTING OR MAKING REPAIRS TO YOUR
WINCH.
WHEN YOU FINISH USING YOUR WINCH UNPLUG THE PLUG FROM THE
SOCKE-[. IF THE PLUG STAYS IN THE SOCKET MOISTURE MAY COLLECT IN
THE SOCKET AND CAUSE A SHORT CIRCUIT.
ANY LIMITED WARRANTY WHICH MAY APPLY TO THIS PRODUCT MAY BE
VOID IF SAID PRODUCT HAS BEEN DAMAGED DUE TO ACCIDENT, UN-
REASONABLE USE. NEGLECT, MODIFICATION, OR FAILURE TO OBSERVE
THESE SAFETY RULES.
H
SECTION I
NOTE:
INSTALLATION/WIRING
Be careful to mount yourwinch in a location with enough supportto handle therating of the winch.
Alittlecommon sense when mounting will help eliminate hazards.
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For mounting on a vehicle with a trailer hitch
we recommend the Powerwinch Multi-Purpose
Adapter Plate (optional accessory _79085)
on Model 316.
This method is the most versatile, as move-
ment from front of vehicle to the rear--or
from vehicle to vehicle is possible.
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The beds of most trucks are not made to
suppo'rt the pulling capacity of your Power-
winch, and should be reinforced with a steel
plate callable of withstanding the rating of
your winch.
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The Harness Assembly Instructions for Model
316 are Included In the poly bag for the parts.
VR-192 WIRING INSTRUCTIONS:
STEP 1
Connect the BLACK wire Io the negative (-) terminal of
your battery or ground it to the vqphlcle frame.
NOTE: If the winch ts mounted at the rear of the vehicle
make the ground connection to the frame.
STEP 2
If the frame is used as aground;.
a. Sandpaper both sides of Ihe metal areas where you are
attaching the wire.
Use the #8-5116" ring l'a,rminal and attach il to the wire.
(Use aterminal crimper and wire Stripper.)
c.Attach the wire to the frame with a5/16" bolt. nut, and
Iockwasher (not supplied), as shown in Fig. 2.
STEP 3
&Connect the RED wire to the circuit breaker. See Fig. 3.
b. Place the wire where you can easily attach it to your
starter solenoid or to the positive (÷) terminal of your
vehicle battery.
Do Not Connect The Circuit Bresker To The Stirrer
Solenoid Or B=ttcr)* Until Steps 4, 5 and 6Ass
C'ompleted.
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Powerwinch
STEP 4
Run the RED wire under or through the vehicle I0 the
Powetwinch. If you need to drill holes to feed the wires.
be sure the wires are prolected from damage. It is a good
idea to usa grommets Jnot supplied), Wire Insulation can
rub off and cause short circuits if grommets are not used,
See Fig. 4.
FIG. 4
_q:41 _a.uk..U, ..... -_STEP 5
Use "twisties" or nylon wire ties (not supplied) to secure
the wire Io the frame of the vehicle about every 18"
along the way, You can also use electrician's tape.
Be Sure Wires Do Not Hang Down And Are Away
From All Moving Pans And Hol Parts, Such As The
Exhaust System.
STEP 6
Place the winch in its working position and decide how
much wire you need to reach the sockeL Add an extra 6"
to each wire and cut off the reel Strip off _" of insula-
tion from each wire. Put the RED wire in the GOLD
terminal of the plug, and the BLACK wire in the SILVER
lerminal, as shown in Fig. 5. Firmly tighten the screws
thai hold the wires in place. Fasten the top tothe plug
using three screws.
_R[D W_R[ (÷l ._S/O'STRIP M (el
FIG. 5
Incorrect Widng Will Short Circuit And Damage
Your Circuit Breaker Which Could Damage Your
Vehicle And The Winch.
STEP 7
With all wires securely tied down and connecled to the
plug. connect the circuit breaker to the solenoid, or
battery, as shown in Fig, 6, !
_e_o thee •
Now you are ready to use your winchl
Temporary Wiring
To use your winch wtth atemporary wire hook-up:
1.Attach two (2) "Alligator'* type clips to the ends of the
RED and BLACK wires.
2. Run the RED wire to the battery and clip it to the hot
--Positive (+)--side.
3. Clip the BLACK wire to the vehicle frame.
NOTE: The voltage output of an automotive battery
is 12 volts. With an alternator and the motor running.
13 volts are available. However, voltage Is '*lost" as
the current travels through the many connections and
down the wire.
For example: the current has to travel 25 feel (from
the vehicle battery to the winch). One volt is "lost"
for every 8 feet of wire. Consequently. only 9 volts
are available lot use by the winch.
As all ratings are given assuming use of this long
harness. Perfon_anco (speed and maximum load
capacity} will increase markedly as the harness Is
shortened up (up Io 25% to 30% if the battery is located
next to the winch).
SECTION II
HOW TO USE YOUR WINCH
Always leave the last three (3) turns of cable
on the drum. This prevents the cable fastener
from pulling out under heavy load.
•The winch cable Is a high quality aircraft
cable selected to withstand loads in excess
of the rated capacity. NEVER exceed this
rating when using the winch.
=,Inspect the cable pedodically for individual
strand breakage or abnormal stiffness.
NEVER replace cable with one of smaller
size and capacity. Check the cable fittings
for tightness. Cable life can be increased
up to 300% by frequent lubrication with a
good grade of oil.
= Keep handsand fingers clear of thedrum
and cablearea ofthe winchwhen
operating.
• Model VR-192 is provided with an emergency
crank handle, and it is available as an optional
accessory for the 316.
DO NOT USE it as an ';assist" to the motor
when the motor is running.DO NOT leave the
crank handle on the winch or run the winch
whilethe handle is attached.
•The winch must be securely attached to
astructural member or frame that Is
capable of sustaining loads In excess of
the winch capacity. When attachlng the
winch to a vehilce, make sure the mounting
pad area is rigidly supported by the vehicle
frame.
• ALWAYS block the wheels to prevent the
vehicle from rolling when pulling a load
with the winch.
•Keepthe winchingarea free of all unneces- •
saP/personnel.
•NEVER stand between the load and the
winch.
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Do not wrap the cable around a load and hook
to self. When attempting to do this use the
Powerwlnch "eco-strap" to Insure the cable
does not fray or kink. See below for do and
don't examples.
DO!
-t

SECTION II
HOW TO USE YOUR WINCH
NOW USE YOUR WINCH
TrI-Matlc Control Knob and Cable
The Tri-Matic Control Knob on the side of the winch
controls the braking of the winch. Turn the knob all
the way counterclockwise .._3. This releases the
clutch and brake so the cable can be pulled out.
To Pull The Cable Out By Hand
t. Turn the Td-Matic Control Knob counterclock-
wise,LF) as far as it will go.
2. Pull the cable out by the hook to the length you
wanL
Always Leave The Last Three [3) Turns Of
Cable On The Drum. This Prevents The
Cable Fastener From Pulling Out Under
Heavy Load.
Winch A Load Under Power
1. Turn the Tri-Matic Control Knob clockwise r'_
until fingertip tight only! DO NOT overtighten or
the clutch will be damaged•
2. Press the button on the remote control to winch
in the load.
Never Winch ALoad With Your Vehicle's
Automatic Transmission in "Park." This
Could Damage Your Transmission. Put
Your Vehicle In "Neutral" With Your Emer-
gency Brake On, And Block The Wheels.
Winch Objects To Your Vehicle
1. Do not jerk any object free using vehicle power.
This will cause severe shock damage to the
winch.
2. Keep the vehicle standing still with the engine
running and the transmission in Fig. 8. Use your
emergency brake and block the wheels.
"_..J=cl
FIG. 8
Keep Vehicle Engine Running Full Power
Your winch will run" at its best if it gets full power
from your battery and alternator. To be sure of this
keep the vehicle engine running.
When To Use Your Emergency Hand Crank
The Emergency Hand Crank should ONLY be used
when there is NO electric power--for example: a
dead batlery. It should NEVER be used to help out a
|
running motor. This could damage the winch and/or
hurt the user.
"HandCrank is optionalon Model 316.
How To Use Your Emergency Hand Crank
(See Fig. 10)
1. Tighten the Td-Matic Control Knob all the way
clockwise("_or there isno braking action.
2. Remove the outernut.
3. Put the Emergency Hand Crank on the shaft.
4. Replace the outernut.
When you have finished using the Emergency Hand
Crank:
1. Remove the outernut.
2. Remove theEmergency Hand Crank.
3. Replace the outernutfor locking.
VR-192 Shown. On Model 316 attach hand crank
on tri-knob shaft.
RG. 10
A Caution: Be Careful Wlth The Cable Hook
DO NOT let the cable hock go into the drum area of
the winch. (The drum area is where the cable
winds.) The hook will bend the levelwind plate or the
levelwind spring if it goes too far into the winch.
Your motor will Idle for •second or two after
the winch Is released and about 1foot of cable
will unwind. Be sure to allow for thisl
Remove The Plug When Winch Is Not fn Use
Inspect the cable often and spray with a light oil or
LPS-3. We recommend spraying the cable once a
week if in regular use.
Gears - Every 6 Months
To grease the gears:
1. Remove the Td-Mafic Control Knob
(Part =79402}.
2. The right and left Side Covers.
3. Use any marine type grease.
SECTION. III
MAINTENANCE/SERVICE
A. CABLE--Lu_icate the cable occasionallywith
Whitmore's Wire Rope Spray, WD40 or a similar
product.Spray the drumand the cable as it is
being wound.
B. IMPROPERLY WOUND CABLE--If for some
reason yourcable is notpropedy wound
(either wound loosely or wound on one side)
unwind the cable and rewind under power,
keeping tensionon it.This should wind the
cable tightlyand evenly. Otherwise the wrap
of the cable may squeeze down to a lower
layer--causing stlckin_ loss of power, and risk
damage to the levelwlnd spdngs.
C. REPLACING THE CABLE--Cut end remove
the old cable from the drum.Insert the new
cable Intothe drum shafthole at theend
opposite thecounterborod end. Draw the cable
through the hole and outthe counterbored side
of the shaft. Push the cable through the fastener'
until It ISflush withthe shoulder end, and soit-
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MODEL VR-lg2 ONLY
A. The Tri-matic Roll-n-Gage Control isthe heart
of your Powerwtnch uniL it controls loading,
unloading and braking.
B. Since this isa highlyengineered assembly, care
should be taken on its maintenarice.
C. To lubricate, remove nut(79720} and unscrew
Tri-matic Control Knob =79402. Remove case
on control side, putcontrol knob back on so
thatparts of the Roll-n-Gage Control will notslip
off.
Using a good grade grease° lubricate the stud,
=71101, thrust beadngs =71609, roller clutch bear-
Ing Inside =71716 compound ddve gear and needle
beadng Inside =71755 compound pinion clutch gear
assembly and needle thrust beadng =71609.
i
solderthe end of the cable to the fastener.
Insert thecable fastener intothecounterbored
hole In thedrum shaft, tapping lightlyuntil the
topof thefastener is flushwiththe drumshaf'L
Bend the cable sharply around the firstgrooveof
the drumshaft.Rewind the cable ontothe drum
under power, keeping tensionon the cable.
WARNING: When replacing thecable, use anexact
replacement cable. The winch rating and cable
strength are carefully matched. Your warrantyis
void if any other cable is used.
D. CARE OF THE LEVELWIND SPRINGS ON
DRUM--Your motorwill continue torun for a
secondor twoafter the spdng loaded switch
Isreleased, especially withouta load. Be sure
to allow for this. Don'tlet thehook go intothe
winch and bend the levelwind springs. When
winding cable onto the drum wIthno load, keep
the cable tautgoing intothe drum.
NOTE: Extreme care should be taken to avoid
getting any grease on clutch lining,1t73602, as this
may cause slippage.
CAUTION: Do not tryto remove bearings from
insidecompound drive gear or compound pinion
gear.
\.,//,_ _# :;)s

SECTION IV EXPLODED PARTS DRAWING

KEY #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
4O
41
42
43
44
45
46
47
48
49
PART #
23
16
15U
33
C12
13
25
C6A
35
303
3AR
32
A37
29W
5-47B
C41N
C41 R
C41 S
ID #
78161
78118
78604
78113
74100
72012
72203
71721
70204
70203
79712
71704
76107
71212
75302
73601
72999
79405
71779
71822
71956
71303
71865
71955
70143
79028
79713
75603
71770
79852
75600
71903
73853
77041
79014
71887
78530
78160
78106
74021
79719
75603
79584
78128
79544
79703
78531
78602
78305
DESCRIPTION
Socket
Solenoid
12-10 Ring Terminal
Switch for Remote Control assy.
Remote control housing
Motor
Motor Strap
Motor Gear
Levelwind spring retainer
Levelwind spring
1/2-20 Nut
Pinion Gear
Bearing
Rear Shaft
Clutch Plate
Clutch Lining
Clutch Gear
Clutch Knob
Drum Gear
Spacers
Drum Flange Split
Drum Shaft
Cable Fastener
Drum Flange Solid
Frame
3/8 Nut
1/2-20 Thin Nut
Compound Gear Stud
Compound Gear
Split Ring Retainer
Pawl Stud
Pawl Spring
Pawl
Crank Handle (optional)
Lanyard Cord (opt!onal)
3/16 x 30 Cable
15 ft. 12 ga. Red Wire
Plug
Circuit Breaker
Cover
6-32 Acorn Nuts
Cover Rod
1-32 x 1/2 Self Tap Screw
Boot
5-40 Flat Head Screw
5-40 Nut
5 Ft. 12 ga. Black Wire
12-10 56 Ring Terminal
Remote Switch assy.
QTY USED
2
1
1
1
1
1
2
1
3
1
5
1
4
1
2
2
2
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
4
1
4
4
1
1
1

TO MAINTAIN EFFICIENCY OF UNIT LUBRICATE
CABLE OCCASIONALLY WITH WHITMORE'S
WIRE ROPE SPRAY--LPS-3, OR
SIMILAR PRODUCT.
THIS IS A PERMANENT MAGNETIC MOTOR
AND IS POLARIZED FOR ROTATION.
Make sure your wiring connections conform to instructions.
Reversing may cause motor gear to back off the threaded shaft,
and/or possible damage to motor or wiring.
VR-1
16
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64
14
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73.---.0
67 68 sty8RINGTERMINAL

#3910-0M
279402 Knob
3 71902 Backlash spring 2
4 71612 Thrust race .030
5 79800 Spring washer 2
6 71613 Thrust race .060 3
771609 Bearing_ 2
8 71755 PinionGear 1
9 73602 Clutch lining 1
10 71716 Powdered metal gear 1
1
11 79715 %-18 hex nut 1
12 71605 Bearing 1
13 71101 Clutch assy stud 1
14 70132 Frame
15 71820 Spacing Washer 1
1
16 71953 Drum shaftflange 1
17 79087 Drum collar 1
18 71858 7/32 cable fastener
19 71402 Drum shaft 1
20 71951 drum shaft flange 1
21 71821 Spacing washer 3
2
22 71606 Bearing 1
23 71751 Gear 1
24 79716 3/4-16 hex nut
25 79712 1/2-20 hexnut 4
26 71703 Drive gear 1
27 71822 Spacing washer 5
28 71818 Shaft spacer 1
1
29 71607 Bearing 1
30 79851 Snap nng
31 71608 Bearing 2
1
32 79713 1/2-20 shaft nut
33 72111 Motor spacer 2
34 71301 Intermediate shaft 1
35 71704 Pinion gear 2
36 -71708 idler gear 4
37 70205 Leve[wind plate 1
1
38 71772 18T motor gear 1
39 72003 Motor
40 72203 Motor straps 2
41 71819 Rear shaft spacer 1
1
42 71201 Rear shaft
43 71817 Shaft spacer "B", 1
44 71816 Shaft spacer "A' 1
2
45 79703 5-40 nut
46 78161 Socket 1
47 79544 5-40 x 1/2 screw 2
48 78108 Buss bar 1
49 78118 Solenoid 1
50 78003 Wire assy 5" red 1
51 78016 Wire assy 6" brown 1
52 78018 Wire assy 11=red 1
53 78017 Wire assy 6" black 1
54 78103 Socket 1
55 79701 10-32 hex nut 3
56 79567 10-32 x 1/2 screw 3
57 78105 Plug 1
58 78113 Sw#.ch 1
59 74100 Remote switch housing 1
60 78553 Remote wire 96" black 1
1
61 78160 Plug
62 79719 6-32 acorn nut 4
1
63 74160 Case grey
64 75603 Cover rod 2
65 79584 10-32 x 3/8 screw 4
66 78601 3/16 ring terminal 1
67 79085 Adapter plate 1
68 77041 Crank handle 1
69 71888 7/32" x 40' easel 1
70 79043 Pulley block and hook 1
71 78105 Plug 1
72 78510 15 ft.8 ga. red wire 1
73 78511 5 ft 8 ga_black wire 1
74 78322 Circuit breaker 1
75 78603 5/16 ring terminal 1