PREMIER WINCH DV-6000S User manual

1
Self-Recovery Winch
Thank you for purchasing a PREMIER WINCH. This manual covers operation and
maintenance of the winch. All information in this publication is based on the latest
production information available at the time of printing.
General Safety Precautions
Every PREMIER WINCH is designed to give safe and dependable service if operated
according to the instructions. Read and understand this manual before installation and
operation of winch.
Follow these general safety precautions:
˙Confirm that the winch is suitable for the operation and conditions
˙Ensure that the winch is securely mounted and the rope wound correctly.
˙Don't use unsuitable pulleys or accessories.
˙Genuine replacement parts should only be used.
˙Check the winch for smooth operation without load prior to any recovery.
˙Make sure the wire rope is wound evenly on the first layer on the drum, rewind it if not.
1. The winch is designed as a vehicle self-recovery unit and only rated for
intermittent-periodic duty.
2. The winch is not to be used to lift, support or otherwise transport personnel.
3. A minimum of five (5) wraps of rope must remain on the drum at all times to support
the rated load.
4. When choosing a winch, you need to consider the vehicles size and weight. As a
general guide, you will need a winch with a maximum load rating of at least one to
one and a half times greater than the gross vehicle weight.
5. The rated line pull of the winch must be powerful enough to overcome the added
resistance caused by whatever the vehicle is stuck in.
WARNING

2
Fleet angle
Centre line of anchor
point
I.Safety Precautions
This winch is designed to give safe, dependable service and trouble-free operation. Please read and
understand this Instruction Manual before installing and operating your winch.
Precautions before use:
Confirm that the winch is suitable for the application before use.
Because the maximum load capacity decreases corresponding to the increase in the number of
layers, wind the rope according to the instructions in this manual.
Mount the winch securely and ensure that the rope is attached correctly.
Genuine replacement parts should only be used.
If a hook or pulley blocks are to be used, ensure that they are correct for the application, and
remember that a pulley block should be rated at least twice the capacity of the winch.
Precautions at the time of operation of the winch are listed as follows:
The operator of a winch in some cases, is required to hold qualifications
according to applicable laws and ordinances.
Only a responsible person should operate the winch.
Prior to use, carry out the daily checks without fail, and use only
after confirming the winch is functioning correctly.
Aminimum of 5 wraps of rope must remain on the drum at all times!
Do not use winch to move people
Keep hands clear of wire rope and fairlead opening.
Use leather gloves or a heavy rag when handling the wire rope.
The winch is not to be used as a lifting device or a hoist for vertical lifting
(Fig1)
Do not exceed maximum line pull ratings shown in these instructions.
Do not impose shock loads on the winch.
Pull from an angle below 15 degree when straightening up the vehicle or
load. (Fig 2)
Run the engine during winching operations to keep battery charged.
When winching a heavy load, lay a heavy
blanket or jacket over the wire Rope, near to
the hook end.
Always operate your winch in an
underwound orientation only. (Fig3)
(Fig 1)
(Fig2)
(Fig3)

3
II.Performance Data
Specifications
Model
DV-6000S
DV-9000ES
DV-9000i
DV-12 light
DV-12000ES
DV-15000ES
Line Pull (first layer)
2,722kg / 6,000lb
4,082kg / 9,000lb
5,443kg/12,000lb
5,443kg/12,000lb
6,803kg/15,000lb
Line Speed (first layer, no load)
8.0mpm / 26.2fpm
13.4mpm / 44fpm
8.0mpm / 26.2fpm
8.3mpm/27fpm
6.9mpm/22fpm
Line Speed (first layer, full load)
2.0mpm / 6.5fpm
2.0mpm / 6.4fpm
1.0mpm / 3.3fpm
1.2mpm/4.0fpm
0.8mpm/2.5fpm
Amp. Draw
no load 12V
60A
55A
50A
60A
60A
full load 12V
300A
350A
350A
440A
460A
no load 24V
35A
30A
30A
50A
50A
full load 24V
200A
210A
210A
290A
340A
Motor
Type
Series wound
Output
12V
2,390w / 3.2hp
3,430w / 4.6hp
3,430w / 4.6hp
4,175w/5.6hp
24V
1,490w / 2.0hp
1,940w / 2.6hp
1,940w / 2.6hp
2,684w/3.6hp
Gear Train
Type
3 stage planetary
Ratio
216:1
156:1
211:1
261:1
315:1
Clutch
Rotating ring-gear
Brake
Automatic, full load CBS (Cone Brake Structure)
Control
Detachable control
box
Detachable
control box
Bridge
control box
Detachable control
box
Detachable control box
Wire Rope
Type
Galvanized aircraft A7 x 19
6 x 29-IWRC
Length
24.4m / 80ft
30.5m / 100ft
25m / 82ft
38m / 125ft
27m / 89ft
Size
7mm / 9/32”
8mm / 21/64”
9.5mm / 3/8”
9.5mm / 3/8”
11mm / 7/16”
Performance
Layer
Model
DV-6000S
DV-9000ES
DV-9000i
DV-12 light
DV-12000ES
DV-15000ES
1st
Layer
Line Pull
kg / lb
2,722 / 6,000
4,082 / 9,000
4,082 / 9,000
5,443 /
12,000
5,443 /
12,000
6,804 /
15,000
Total Rope on
the Drum m/ft
3.8 / 12.5
6.1 / 20.0
6.1 / 20.0
5.4 / 17.7
6.6 /21.5
5.7 / 18.6
2nd
Layer
Line Pull
kg / lb
2,266 / 4,995
3,316 / 7,310
3,316 / 7,310
4,319 /
9,522
4,563 /
10,060
5,569 /
12,277
Total Rope on
the Drum m/ft
8.4 / 27.5
13.6 / 44.7
13.6 / 44.7
12.2 / 40.0
14.4 / 47.2
12.6 / 41.4
3rd
Layer
Line Pull
kg / lb
1,941 / 4,279
2,792 / 6,154
2,792 / 6,154
3,580 /
7,893
3,928 / 8,659
4,713 /
10,391
Total Rope on
the Drum m/ft
13.7 / 45.0
22.6 / 74.0
22.6 / 74.0
20.5 / 67.3
23.5 / 77.0
20.8 / 68.3
4th
Layer
Line Pull
kg / lb
1,697 / 3,742
2,410 / 5,314
2,410 / 5,314
3,056 /
6,737
3,448 / 7,601
4,086 / 9,007
Total Rope on
the Drum m/ft
19.8 / 65.1
30.5 /100
30.5 /100
25.0 / 82.0
33.8 / 110.9
27.1 / 89
5th
Layer
Line Pull
kg / lb
1,508 / 3,325
3,072 / 6,774
Total Rope on
the Drum m/ft
24.4 / 80
38.1 / 125

4
Main Components

5

6
How the winch is rated.
Load and speed vary according to how
much wire rope is on the drum. The first
layer of rope on the drum delivers the
slowest speed and the maximum
load. A full drum delivers the maximum
speed and the minimum load. For this
reason, winches are rated on their performance
first layer of rope.
III.Installation
Before using the winch, make sure all electrical components have no corrosion or damage; the
environment should be clean and dry. Voltage drop from the battery connections to the winch must
not exceed 10% of the nominal voltage under normal operating condition.
Mounting
1. It is very important that the winch be
mounted on a flat and hard surface in order
to make sure the motor, drum and
gearbox housing are aligned correctly.
2. It is recommended that you use a
mounting channel to prevent from
damaging winch or vehicle.
3. It is also recommended that the roller fairlead must be fitted to prevent excessive wear of the
wire rope.
4. Tighten all mounting nuts on motor and roller fairlead securely.
Battery cable connection
Battery cable specification:
Model
DV-6000S
DV-9000ES / DV-12 light
DV-9000i
DV-12000ES
DV-15000ES
Control Type
Detachable control box
Bridge control box
Detachable control box
Volt
12V or 24V
Red cable: 4AWG X 1.83m/72”
Red cable: 2AWG X 1.83m/72”
Red cable: 2AWG X 1.83m/72”
Black cable: 4AWG X 1.8m/70”
Black cable: 2AWG X 1.8m/70”
Black cable: 2AWG X 1.8m/70”
1. Attach the black cable (earth) firmly to the chassis of the vehicle or to the negative –battery
terminal.
2. Attach the red cable to the circuit breaker, connect the other end to the positive +battery
terminal.
3. The circuit breaker must be fitted.
DV- 6000S/9000ES/12 light
12000ES/15000ES
DV- 9000i

7
DV-6000S DV-9000i
DV- 9000ES / DV-12 light
DV-12000ES/15000ES
Switch Connection
1. Ahand-held remote switch withψ2.0mm X 3c X
3m/ψ1/12” X 3c X 10’ cord supplied
2. Open the dust-proof cover of the winch, then
insert the switch plug into the socket (fig4).
IV. Operation
Precautions
Check all safety and environmental conditions prior and during use.
A wire rope should be replaced if it shows signs of excessive wear, broken wires, corrosion or
any other defect.
The operator must remain with the winch when it is being operated.
The winches duty rating is S3 (intermittent –periodic)
If the winch fails to pull a load under normal conditions, stop the operation within 30 seconds
otherwise motor damage may occur.
Ensure that the winch is connected to the correct voltage. 12VDC or 24VDC only
Check that the clutch lever is in the “Engaged” position during and after use.
Remove the pendant from the winch when not in use.
Do not wrap the wire rope around the load and back onto it self. Always use a strap to ensure
that the wire rope does not fray or kink
Keep hands and clothes away from the winch, wire rope, and fairlead.
Never unplug the pendant when winching a load.
Before use, ensure that you are familiar with all winch operations (winch speeds & direction).
To avoid insufficient power when winching a load, the vehicle should be running and in
neutral.
Keep the pendant cord clear of the winch cable at all times.
If noise or vibration occurs when running, stop the winch immediately and return it for repair.
(Fig4)

8
Cable-Out Cable-In
Cable-in/ Cable-out Operation
1). To determine “Cable - Out”, depress ↑ button (fig.5)
2). To determine “Cable - In” depress ↓ button (fig.6)
To stop winching, release the button
(Fig5) (Fig6)
Free Wheel (Clutch) Function
The clutch allows rapid unspooling of the wire rope for hooking onto a load or anchor points and is
operated by a clutch lever.
The clutch lever must be in the “Engaged” position before winching.
1). To disengage the clutch lift the clutch lever up and turn it at 900clockwise rotation to the
“Disengaged” position, wire rope can now be free spooled off the drum.
2). To engage the clutch lift the clutch lever up and turn it at 900counter-clockwise rotation to the
“Engaged” position.
3). If a clutch lever can’t be properly locked in the “Engaged” position, rotate the drum to make the
clutch couple to the gear train.
4). Wear leather gloves and use a handsaver bar when guiding the wire rope off the drum
(Engaged) (Disengaged)

9
Recovery Procedures
Followings are some safety tips to get out
of trouble during a recovery.
1).When using a winch to rescue another car,
the safest and most efficient direction is
to pull in the same direction, which the
car was moving when it became stuck.
2).When a car is stuck on a slope, the safest
way to pull the car is up the slope
3).Using a snatch block will increase the
capacity, but the speed will decrease
accordingly.
4).Experience has shown the best wire rope
service is obtained when the maximum
fleet angle is not more than 15 degree.
Keep the wire rope as close as possible to
the centre line of the anchor point
5).It is the best to work with the most of
wire rope unreeled from the drum to get
more pulling power, but a minimum of
five (5) wraps of wire rope should be
wound around the drum to support the
rated load.
LIFTING
Although Premier DV-9000/DV-9000i have been designed primarily for winching operations , it’s
possible to use the product for hoisting.
Premier Self-Recovery Winches can be used for lifting if you follow these suggestions.
Remove freespool function or make sure freespool is fully engaged before using.
Divide your winches’ rated load by 5. Take this number and reduce it by 10% for the
second and each additional layer of wire rope to be pulled up onto the drum. The
result of this calculation will be the load that you can lift. Don’t forget friction is one
of the important factors.
Operators and all others need to stand well clear of the lifting area.
Never lift people of lift loads over people.
Check local building and machinery codes to be sure you are in compliance before
using your winches.
Please note the winches’ duty rating is S3 (intermittent-periodic).
Do not keep winching in / out if the motor is overheated , or motor will be burnt-out.

10
V. Maintenance
Lubrication
All moving parts in the winch are permanently lubricated at the time of assembly. Under
normal conditions factory lubrication will suffice. If re-lubrication is necessary after
repair or disassembly use a marine type grease.
Cable Replacement
Never use a rope of a different size or material.
Only use genuine replacement parts.
If the winch is subjected to a high duty or excess load, the rope may require frequent
replacement.
1). Disengage the clutch (Fig7)
2). Spool the entire wire rope, and then remove it from the drum.
3). Place the replacement wire rope through the fairlead opening, pass below the
drum, and insert it into the hole on the drum core. (Fig8)
4). Tighten the screw downwards to secure the wire rope (Fig8).
5). Secure a clevis hook to the wire rope by using a clevis pin and cotter pin.
(Engaged) (Disengaged)
(Fig 7) (Fig 8)

11
Maintenance Schedule
Ensure that a responsible person carries out all inspections as per schedule.
Inspections are dived into Daily, Monthly and 3 Monthly.
Classification of check
Item
Checking method
Checking reference
Daily
Periodical
One
month
Three
month

Installation
Mounting bolts & alignment.
Bolt tension & wear.
Existence of abnormalities

Switch
Working
Manual
Reasonable actuation

Wearing in contact points
Visual.
Free of wear or damage.

Wire rope
Broken strands
Visual, measuring (monthly)
Less than 10%


Decrease in rope diameter
Visual, measuring (monthly)
7% of nominal diameter
max

Deforming or corrosion
Visual
Existence of abnormalities

Fastening condition of end
Visual
Existence of abnormalities

Clutch
Wear in spring
Visual evidence of wear
Free of wear or damage.

Motor
Staining, damage
Visual evidence of wear
Existence of abnormalities

Brake
Wearing of lining
Visual evidence of wear
Free of wear or damage.

Performance
Visual
Reasonable actuation

Gear
Damage, wearing
Visual evidence of wear
Free of wear or damage.

12
VI.Trouble Shooting
When the winch fails to operate after several attempts, or if there is any fault while
operating check the following:
Symptom
Possible Cause
Remedy
Winch will not operate
Cut circuit
Check battery lead
Weak battery
Recharge or replace battery (at least 650CCA)
Damaged over-load protector(option)
Replace over-load protector(option)
Bad connection of wiring
Reconnect tightly
Damaged contactor
Replace contactor
Cut circuit on switch
Replace switch
Damaged motor or worn carbon brush.
Replace motor or carbon brush
Poor or lost connections to motor
Replace wiring or tighten it
Motor runs in one
direction.
Broken wiring or bad connections
Reconnect or replace wiring
Damaged or stuck contactor
Replace contactor
Switch inoperative
Replace switch
Drum will not clutch.
Clutch does not disengage
Replace clutch
Damaged 1st shaft
Replace 1st shaft
Damaged brake cam and disc
Replace brake cam and disc
Damaged output shaft
Replace output shaft
No brake
The gear train is mechanically binding up
Check to insure the winch is mounted on a flat, rigid
surface
Damaged brake cam and disc
Replace brake cam and disc
Damaged gear box
Replace gear box
Broken retaining ring
Replace retaining ring
Oil leakage into brake cavity
Repair and clean oil leakage
Damaged or inoperative spiral spring
Replace and position spiral spring
Brake distance is too
long
Worn brake disc or loose brake spacer
Replace brake disc or adjust brake spacer according to
brake adjustment procedures
Oil leakage into brake cavity
Repair and clean oil leakage
Brake will be locked
Too much brake disc powder in the brake hub
Clean brake hub
Over tensioned spiral spring
Adjust tension on spiral spring
Stuck between brake disc and gear box
Replace with new brake assembly
Damaged gear box
Hit by certain exterior force
Replace the damaged components
Damaged gear train
Replace the damaged components
Over load operation
Stop the winch operation and reduce the load
Motor runs extremely
hot
Long period of operation
Allow to cool
Damaged motor
Replace or repair motor
Damaged or inoperative brake
Replace or repair brake

13
VII.Replacement Parts List For DV-6000S

14
Item No.
Description
Qty
1
Motor 12V
1
Motor 24V
2
Tie bar kit
2
3
Motor support rack
1
4
Motor coupling
1
5
Drum bushing
1
6
Drum kit
1
7
Drum bushing B
1
8
Gearbox support rack
1
9
Wire rope w/hook
1
10
1st shaft
1
11
Grounding lead
1
12
3rd ring gear kit
1
13
2nd stage carrier
1
14
1st stage carrier
1
15
Retaining ring
1
16
1st & 2nd ring gear
1
17
1st pinion kit
1
18
Clutch kit
1
19
Gear box kit
1
20
Cone brake disc kit
1
21
Brake clutch base
1
22
Brake cover kit
1
23
Roller fairlead WA-0508
1
24
Mounting hardware
1
25
Remote control WA-0310
1
26
Handsaver strap
1
27
Detachable control box 12V
1
Detachable control box 24V
27-1
Remote socket kit
1
27-2
Detachable control pack 12V
1
Detachable control pack 24V
28
Handle kit
1

15
VIII.Replacement Parts List For DV-9000ES / DV-12 light

16
Item No.
Description
Qty
1
Motor 12V
1
Motor 24V
2
Tie bar kit
2
3
Motor support rack
1
4
Motor coupling
1
5
Drum bushing
2
6
Drum kit
1
7
Gearbox support rack
1
8
Grounding lead
1
9
Wire rope w/hook
1
10
1st shaft
1
11
3rd ring gear kit
1
12
3rd stage carrier
1
13
3rd bushing
1
14
2nd stage carrier
1
15
1st stage carrier
1
16
1st & 2nd ring gear
1
17
1st pinion kit
1
18
Clutch kit
1
19
Gear box kit
1
20
Cone brake disc kit
1
21
Brake cover kit
1
22
Roller fairlead
1
23
Mounting hardware
1
24
Remote control
1
25
Handsaver strap
1
26
Detachable control box 12V
1
Detachable control box 24V
26-1
Remote socket kit
1
26-2
Detachable control pack 12V
1
27
Brake clutch base
1

17
IX.Replacement Parts List For DV-9000i

18
Item No.
Description
Qty
1
Motor 12V
1
Motor 24V
2
Bolt, washer kit
4
3
Motor support rack
1
4
Motor coupling
1
5
Drum bushing
2
6
Drum kit
1
7
Gearbox support rack
1
8
Grounding lead
1
9
Wire rope w/hook
1
10
1st shaft
1
11
3rd ring gear kit
1
12
3rd stage carrier
1
13
3rd bushing
1
14
2nd stage carrier
1
15
1st stage carrier
1
16
1st & 2nd ring gear
1
17
1st pinion kit
1
18
Clutch kit
1
19
Gear box kit
1
20
Cone brake disc kit
1
21
Brake cover kit
1
22
Roller fairlead
1
23
Mounting hardware
1
24
Remote control
1
25
Handsaver strap
1
26
Integrated solenoid pack 12V
1
Integrated solenoid pack 24V
26-1
Remote socket kit
1
26-2
Solenoid right cover kit
1
26-3
Upper Solenoid box
1
26-4
Solenoid pack 12V
1
Solenoid pack 24V
26-5
Solenoid left cover kit
1
26-6
Rubber gland
1
26-7
Tie bar
3
27
Brake clutch base
1

19
X.Replacement parts List For DV-12000ES/15000ES

20
Item No.
Description
Qty
1
Motor 12V
1
Motor 24V
2
Tie bar kit
3
3
Motor support rack
1
4
Motor coupling
1
5
Drum bushing
2
6
Drum kit
1
7
Gearbox support rack
1
8
Grounding lead
1
9
Wire rope w/hook
1
10
1st shaft
1
11
3rd ring gear kit
1
12
3rd stage carrier
1
13
2nd stage carrier
1
14
1st stage carrier
1
15
Retaining ring
1
16
1st & 2nd ring gear
1
17
1st pinion
1
18
Clutch kit
1
19
Gear box kit
1
20
Brake base
1
21
Cone brake disc kit
1
22
Brake cover kit
1
23
Roller fairlead
1
24
Mounting hardware
1
25
Remote control
1
26
Handsaver strap
1
27
Detachable control box 12V
1
Detachable control box 24V
27-1
Remote socket kit
1
27-2
Detachable control pack 12V
1
Detachable control pack 24V
28
Brake clutch base
1