Red Winches COBRA 2 XL User manual

RED Winches
AIR BRAKE FITTED ON ALL OPTIONS
OX MOTOR FITTED ON ALL OPTIONS FOR THE
ULTIMATE POWER BEHIND YOUR WINCHING
This winch is a RED WINCHES designed product, whose designs have undergone
extensive testing. The end user can now enjoy a professional highly engineered,
precision, high performance electric winch capable of operating in the most demanding
of situations.The small compact size combined with its pulling power and billet CNC
housings make it an ideal winch for maximum impact when faced with minimal
installation space
COBRA 2 XL
XL DRUM LENGTH
ADVENTURE GEAR BOX - RATIO 214:1
RATED PULL: 6000KG
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:2
OF
11
REVISION SCALE
1
SHT
A
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
WINCH
TYPE
WINCH
DESCRIPTION:
RED Winches
COBRA2 TECHNICAL MANUAL
ULTIMATE PERFORMANCE WINCH
COBRA 2 (ADV GB)
LOW LINE, SINGLE MOTOR, 12V / 24V DC
AIR BRAKE, FREESPOOL

CONTENTS
WINCH MANUAL COVER 1.
CONTENTS PAGE 2.
WINCH DIMENSIONS 3.
WINCH OVERVIEW DIAGRAM 4.
WINCH EXPLODED DIAGRAM 5.
WINCH PULLEY ARRANGEMENT 6.
WINCH FREESPOOL DIAGRAM 7.
WIRING CONNECTION SCHEMATIC 8.
OX MOTOR DIAGRAM 9.
BRAKE ASSEMBLY 10.
GEAR BOX DIAGRAM 11.
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:10
OF
11
SCALE
2
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
CONTENTS
ULTIMATE PERFORMANCE PRODUCTS

350
119
205.5
330.0
114.5
123 38.0
M12 FIXINGS
12.9 RATED
491.3
175.0
COBRA2 ADVENTURE GEARBOX
WINCH WEIGHT = 39kg
XL DRUM WIDTH
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:4
OF
11
SCALE
3
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
WINCH DIMENSIONS
ULTIMATE PERFORMANCE PRODUCTS

AIR FREESPOOL ASSEMBLY
SHOWN
6MM AIRLINE TUBE REQUIRED
TO FEED PISTON BODY FROM COMPRESSOR
VIA A TOGGLE OR SOLENOID SWITCH
(IF AIR FREESPOOL ORDERED / FITTED)
ALBRIGHT MOTOR CONTROLLER
AIR SOLENOID FOR AIR BRAKE
ULTIMATE BRAKE FOR
YOUR WINCH
AIR BRAKE ASSEMBLY
FITTED TO END OF GEARBOX
HAWSE FAIRLEAD
ALUMINIUM - CNC MACHINED
WITH LARGE RADIUS TO
EXTEND ROPE LIFE
COPPER BUS BARS
FOR THE ULTIMATE
TRANSFER OF POWER
THE MIGHTY OX MOTOR IS A
VERY POWERFUL MOTOR
PROVIDING HIGH SPEED
AND HIGH TORQUE FOR
ALL WINCHING SITUATIONS
ENGINEERED DRUM
SUPPORTED BY PRECISION
SEALED BEARINGS
ADDED PROTECTION
FROM 2 x DRUM END SEALS
PRECISION ENGINEERED
BILLET MACHINED HOUSINGS
AND DRUM ENDS, THE ULTIMATE
IN STRENGTH AND DESIGN
COVER CAN BE REMOVED
EASILY AND THE TWO PULLEYS
SWAPPED OVER TO GIVE THE
WINCH A DIFFERNT RATIO
DEPENDING ON THE TYPE OF
EVENT OR JOURNEY AND
THE VEHICLE YOU WILL
BE USING IT WITH
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:2
OF
11
SCALE
4
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
WINCH OVERVIEW DIAGRAM
ULTIMATE PERFORMANCE PRODUCTS

14
6
16
17
7
3
2
5
19
18
1
2
20
15
8
10
20
9
20
11
23
4
13
24
M12x16 CAP HEADS
FITTED FOR ASSY PROCESS
TO BE REMOVED PRIOR TO
MOUNTING
COBRA 2 (XL)
EXPLODED DIAGRAM
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL
ITEM
NO.
PART / DRG
NUMBER
DESCRIPTION
OX
MOTOR/WITH
BOX/QTY.
1 EXP2-MA-01C_XL COBRA 2 WINCH BODY ASSY 1
2 EXP2-MA-02C_ADV COBRA 2 GEARBOX ASSY-ADVENTURE 1
3 EXP2-MA-04_PF EXPLORER 2 FREESPOOL ASSEMBLY 1
4 EXP2-MD-05C_XL COBRA-2 DRIVE SHAFT - XL 1
5 EXP2-MD-17C END PLATE - COBRA 1
6 EXP2-MD-18_XL EXPLORER FAIRLEAD - XL 1
7 EXP2-MD-28C COVER 1
8 EXP2-MD-36C 24T-10P-16W PULLEY - COBRA 1
9 EXP2-MD-35C 18T-10P-16W PULLEY - COBRA 1
10 EXP2-MD-37C BRAKE DRIVE COUPLING - COBRA 1
11 EXP2-MD-38C BEARING CARRIER - COBRA 1
12 HORNET2-MD-42 AIR SOLENOID BRACKET 1
13 RWM-MA-01 OX MOTOR ASSEMBLY - DC88 1
14 ABU-MA-01 SINGLE MOTOR BRAKE ASSEMBLY 1
15 10PA-560-16 COBRA DRIVE BELT 1
16 M12 FORM C WASHER 4
17 M12 x 30 M12 x 30 CAP HD SCREW 4
18 M12 x 35 M12 x 35 CAP HD SCREW 2
19 M5 x 16 M5 x 16 SKT BUTT HD 6
20 16002 BALL BEARING (32 x 15 x 8) 3
21 61805 BALL BEARING (25 x 37 x 7) 1
22 VL170 SEAL V170 SEAL 2
23 M4 x 12 M4 x 12 SKT CP HEAD 10
24 M8 x 16 M8 x 16 GRUB SCREW 2
25 3V1-06_ASSY AIR SOLENOID 1
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:3
OF
11
SCALE
5
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
WINCH EXPLODED DIAGRAM
ULTIMATE PERFORMANCE PRODUCTS

EXP2-MD-36C
EXP2-MD-35C
10PA-560-16
LARGE PULLEY
SMALL PULLEY
DRIVE
BELT
COVER REMOVED
FOR CLARITY
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:1.5
OF
11
SCALE
6
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
WINCH PULLEY ARRANGEMENT
ULTIMATE PERFORMANCE PRODUCTS

A
A
6MM TUBE REQUIRED
FROM AIR SOLENOID
OR TOGGLE SWITCH
PIN HOLDS PISTON
IN PLACE
SECTION A-A
USE GASKET SEALER
UNDER HEAD OF BOLTS
& DOWN BOLT HOLES
EXP2-MD-16_PF
O-RING-804
O-RING-804
EXP2-MD-15_PF
O-RING-27.5-2.5
063GH 02M
EXP2-MD-14B
EXP2-MD-14A
ROLLPIN
ENGAGE DRUM:
ROTATE AND LOWER
MANUAL FREESPOOL ASSEMBLY (NOT SHOWN)
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL
DRUM FREESPOOL:
LIFT AND ROTATE TO
INITIATE DRUM FREESPOOL MOVEMENT
DRUM FREESPOOL:
SWITCH OPERATED OR WIRELESS
AIR SUPPLIED THROUGH A 2-WAY DC SOELNOID VALVE
AIR FREESPOOL ASSEMBLY (SHOWN)
ENGAGE DRUM:
REMOVE POWER, AIR EXHAUSTS, PIN RE-ENGAGES
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:3
OF
11
SCALE
7
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
WINCH FREESPOOL DIAGRAM
ULTIMATE PERFORMANCE PRODUCTS

AIR BRAKE
LINE
6mm
(SUPPLIED FITTED)
OX MOTOR
12v OR 24V
CAN BE SUPPLIED
DRUM FREESPOOL
LIFT AND TURN: FREE
TURN AND LOWER: ENGAGED
GEARBOX
HOUSING
CONNECTION
SCHEMATIC
ENSURE POSITIVE CABLE LUG IS INSULATED FROM
ACCIDENTAL TOUCHING AND DOES NOT TOUCH ANY
SURROUNDING PARTS OR MOTOR BUZZ BARS
EARTH CONNECTION
FROM BATTERY CAN GO
ON EITHER ONE OF THREE
M8 THREADED HOLES
70mm2 CABLE TO BE USED
POSITIVE 12V CABLE
FROM BATTERY TO BE
CONNECTED HERE
M8 MALE THREAD
70mm2 CABLE TO BE USED
6mm AIRLINE FROM ONBOARD
TRUCK SYSTEM NEEDS TO BE CONNECTED HERE
COMPACT ARB OR EQUIVILENT COMPRESSOR
MIN AIR PRESSURE 4.5 BAR (60 PSI)
WARNING
WINCH OUT 12V
SUPPLY FROM
ROCKER SWITCH
ON YOUR DASH
WINCH IN 12V
SUPPLY FROM
ROCKER SWITCH
ON YOUR DASH
AIR BRAKE
SOLENOID
(SUPPLIED FITTED)
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:3
OF
11
SCALE
8
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
WIRING CONNECTION SCHEMATIC
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL

POSITIVE CONNECTION
BUS BAR COVER
M8 EARTH
CONNECTIONS (3)
O-RING IN END PLATE
WARNING
Never allow the OX motor to 'over-speed' or run in
a no-load situation for too long as the armature could
become damaged through revolving too fast
POSITIVE 12V CABLE
FROM BATTERY TO BE
CONNECTED HERE
M8 MALE THREAD
70MM
2
CABLE TO BE USED
151.0
238.0
171.5
USE SMALL ZIP TIE TO HOLD
THE COVER DOWN WHEN USED
ON ROUGH TERRAIN OR TRAVELLING
AT HIGH SPEED
BRUSH PACK IN
FRONT OF MOTOR
125.0
ALRIGHT HEAVY DUTY
SOLENOIDS
With the appropriate battery and alternator system, these OX motors will
provide tremendous pulling power and a very high drum speed at no-load
when respooling the rope back on to the drum.
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:2
OF
11
SCALE
9
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
OX MOTOR DIAGRAM
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL

UNLESS SPECIFIED
M8
M10
M12
M16
M20
200 Nm
160 Nm
80 Nm
45 Nm
24 Nm
10 Nm
M6
TORQUE
FASTENER
AIR FEED FOR BRAKE
FROM WINCH AIR
BRAKE SOLENOID VALVE
O-RINGS MUST BE ALL
LIGHTLY OILED BEFORE ASSEMBLY
HIGH TEMPERATURE O-RINGS
MUST BE USED
ABU-MD-02
N228
N230
ABU-MD-03
MN036X2.5
C1300-070
ABU-MD-04
ABU-MD-06
ABU-MD-08
1206621_AMTE-M-H-M5
1X
153097_QSLV-1_8-6-I
1X
8 SPRNGS FITTED AS STANDARD
ADDING SPRINGS MAKES THE BRAKE STRONGER
FOR HEAVY VEHICLES
REDUCING SPRINGS MAKES BRAKE SOFTER
FOR LIGTHER VEHICLES
MIN SPRINGS: 6
MAX SPINGS: 12
61805
ABU-MD-05
WARNING
ONLY REMOVE BRAKE DISC
SCREWS WHILE THE AIR IS ON.
AIR MUST BE APPLIED TO THE UNIT TO
TAKE PRESSURE OFF THE BRAKE PADS
BEFORE ATTEMPTING TO REMOVE SCREWS
ENSURE ALL FASTENERS
ARE TORQUED TO THE CORRECT
VALUES
LOCTITE 234 (THREADLOCKER)
TO BE APPLIED ON ALL FASTENERS
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:2
OF
11
SCALE
10
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
BRAKE ASSEMBLY
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL

A
A
SECTION A-A
SCALE 1 : 1
24T
18T
18T
18T
DRIVE
EXP2-MD-13C
COBRA 2
ADVENTURE
GEARBOX
BEARING
INTERNAL SPUR GEAR
ANNULUS RING GEAR
PG4
PG1
PG2
PG3
4205 ATN9
Drawing not to be reproduced or distributed in any format or method without specific permission from Red start//Design .
1:2
OF
11
SCALE
11
SHT
DRAWING NUMBER:
www. red -winches.com
Telephone: [phone]
Email: [email protected]
TITLE
RED Winches
ADVENTURE GEARBOX DIAGRAM
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 ADVENTURE GEARBOX - TECHNICAL MANUAL