Red Winches Cobra-2 Instruction manual

This winch is part of a group of winches whose designs have undergone
extensive testing. The end user can now enjoy a professional highly engineered
high performance electric winch capable of operating in the most demanding of
situations.The small compact size combined with its pulling power make it an
ideal winch for maximum impact when faced with minimal installation space.
COBRA-2 - SINGLE MOTOR WINCH
WORKSHOP MANUAL WITH DRAWINGS
RED
Winches
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TITLE
RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
REDWINCH COBRA 2 - WORKSHOP MANUAL

UNLESS SPECIFIED
M8
M10
M12
M16
M20
200 Nm
160 Nm
80 Nm
45 Nm
24 Nm
10 Nm
M6
TORQUE
FASTENER
222
42
373 20
6mm AIR TUBE
FEEDS BRAKE
SOLENOID HERE
8.0
MINIMUM MATERIAL
THICKNESS OF 8mm
TO BE USED FOR WINCH
TRAY OR MOUNTING PLATE
431.50 27
254
114
56 122
33
TYP
MOUNTING
BOLTS x 4
M12 x 24 DEEP
8 PLACES
NETT WEIGHT: 30 Kg
PACKED WEIGHT: 35Kg
ENSURE ALL FASTENERS
ARE TORQUED TO THE
CORRECT VALUES
LOCTITE 234
(THREADLOCKER)
TO BE APPLIED ON ALL
FASTENERS WHEN
WINCH IS FITTED
REV. DATE DESCRIPTION CHANGED BY
A 01/07/2019 PRODUCTION ISSUE NJ
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TITLE
RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - DIMENSIONS / LAYOUT

MOTOR END HOUSING
ALUMINIUM
FAIRLEAD WITH
LARGE RADIUS TO
PROTECT ROPE
TOP VIEW
COVER REMOVED TO SHOW
BUS BAR ARRANGEMENT
A
F1
F2
POSITVE CONNECTION
FROM YOUR BATTERY
(70mm² CABLE MIN)
AIR BRAKE
PNEUMATIC CONNECTION
(AIR IN) FACTORY FITTED
AIR FREESPOOL
PNEUMATIC CONNECTION
6mm OD TUBE (AIR IN)
COPPER BUS BAR
SET GIVING (75mm2)
ON EACH LEG
FRONT
12v OR 24v
OX MOTOR
AIR BRAKE ASSEMBLY
GEARBOX
LEFT SIDE
FREESPOOL
END COVER
REAR VIEW
ALBRIGHT
MOTOR
SOLENOID
BUS BAR COVER
EARTH TO BATTERY
GOES HERE: M8 BOLT
3 x TAPPED HOLES
ARE AVAILABLE
AIR BRAKE
PNEUMATIC CONNECTION
6mm OD TUBE (AIR IN)
AIR
BRAKE
SOLENOID
PULL: 4500KG
POWER: 12 or 24vDC
BRAKE: AIR (MIN 5 BAR - 70psi)
FREE-SPOOL: AIR (MIN 5 BAR - 70psi)
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TITLE
RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - FEATURES AND COMPONENT PARTS

STANDARD GEARING SETUP
SMALL PULLEY ON TOP
LARGE PULLEY ON THE BOTTOM
FINAL RATIO: 108:1
END COVER
REMOVED TO
SHOW PULLEY
SYSTEM INSIDE
83 (REF)
59 (REF)
175.00
OVERDRIVE GEARING SETUP
LARGE PULLEY ON TOP
SMALL PULLEY ON THE BOTTOM
FINAL RATIO: 61:1
PULLEYS CAN BE SWAPPED OVER EASILY
USIGN A FEW BASIC TOOLS.
GIVING YOU TYHE CHANCE TO CHANGE
THE RATIO AND SPEED OF THE WINCH TO MEET
THE DEMANDS OF THE TRIP OR EVENT
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TITLE
RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH - COBRA 2
GEARING SETUP - STANDARD / OVERDRIVE

FREESPOOL END COVER
FREESPOOL END HOUSING
MOTOR ASSEMBLY
DRUM ASSEMBLY
AIR BRAKE
DRIVE HOUSING
GEARBOX HOUSING
GEARBOX
FAIRLEAD
TIE BAR
AIR BRAKE SOLENOID
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RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - EXPLODED VIEW

NOTE:
AIR BRAKE MUST BE RELEASED
AT THE SAME TIME THE WINCH
IN OR WINCH OUT SIGNAL IS
GIVEN
THIS IS WHAT THE DIODE INSIDE
THE AIR SOLENOID CAP
DOES FOR THE WINCH
EARTH TO
BATTERY
M8 BOLT
AIR FREESPOOL
CONNECTION
6mm OD TUBE
(2m PROVIDED)
AIR FREESPOOL FEED COMES FROM
YOUR ONBOARD COMPRESSOR VIA
YOURT SOLENOID VALVE OR PNEUMATIC
TOGGLE SWITCH
THESE SWITHCES OR SOLENOIDS NEED TO BE
ORDERED SEPARATELY AND DO NOT NORMALLY
COME WITH THE WINCH
DETAIL B
SCALE 1 : 1.5
12v or 24v POSITIVE FEED
FROM YOUR VEHICLE
M8 BOLT CONNECTION
(70mm
²
CABLE MINIMUM)
12v SIGNAL
WINCH IN
(BROWN WIRE)
EARTH
CONNECTION
(BLACK WIRE)
12v SIGNAL
WINCH OUT
(RED WIRE)
AIR SOLENOID FOR
AIR BRAKE
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TITLE
RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - HOW TO OPERATE

10
1
4
5
8
3
9
3
11
12
6
7
2
ITEM NO.
DESCRIPTION
OX
MOTOR/
Default/Q
TY.
1
COBRA END HOUSING ASSEMBLY
1
2
DRIVE SHAFT & FREESPOOL ASSEMBLY
1
3
COBRA WINCH BODY ASSEMBLY
1
4
HAWSE FAIRLEAD
1
5
M10 x 40 CAP HD SCREW
8
6
M12 x 40 CAP HD SCREW
4
7
WASHER
4
8
SINGLE MOTOR BRAKE ASSEMBLY
1
9
COBRA WINCH DRUM ASSEMBLY - STD
1
10
OX MOTOR ASSEMBLY
1
11
AIR SOLENOID
1
12
AIR SOLENOID BRACKET
1
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RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - TOP LEVEL PARTS LIST

MOTOR
ASSEMBLY
AIR
BRAKE
DRIVE
SHAFT
FREESPOOL
CLUTCH PLATE
WINCH BODY
GEARBOX CASSETTE
FAIRLEAD
END COVER
FREESPOOL PLATE
DRIVE PINS
TIE BAR
END COVER
DRIVE BELT
DRIVE PULLEY
GEARBOX RING GEAR
GEARBOX DRIVE GEAR
PULLEY
DRIVE SHAFT
DRUM SEAL
DRUM BEARING
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RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - EXPLODED VIEW

ABU-MD-01
1x
N228
1x
ABU-MD-02
1x
N230
1x
ABU-MD-03
1x
C1300-070
1x
ENTEX-91
6x
ABU-MD-04
1x
ABU-MD-05
3x
ABU-MD-06
1x
ABU-MD-08
1x
M5 x 16
3x
61805
1x
MN036X2.5
1x
153097_QSLV-1_8-6-I
1x
1206621_AMTE-M-H-M5
1x
LOCTITE
SCREW LOCK
B243
LOCTITE
SCREW LOCK
B243
LIGHT OIL
ALL O-RINGS
PRIOR TO ASSEMBLY
LIGHT OIL
BORE PRIOR
TO ASSEMBLY
ABU-MD-07
2x
ABU-MD-09
8x
BRAKE SPRINGS
BRAKE SPRINGS FITTED
INTO THESE HOLES EQUALLY SPACED
M4 x 16
4x
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RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - AIR BRAKE ASSEMBLY

UNLESS SPECIFIED
M8
M10
M12
M16
M20
180 Nm
130 Nm
65 Nm
35 Nm
20 Nm
10 Nm
M6
TORQUE
FASTENER
LIGHTLY GREASE
GROOVES OF SPLINE
ON ASSEMBLY WITH
COPPER SLIP GREASE
SPRAY WITH DUCK OIL
ALL OVER AFTER IT HAS
BEEN ASSEMBLED INTO
WINCH
VIPER-MD-53
1X
N809
1X
VIPER-MD-46
1X
N109
1X
VIPER-MD-45
1X
ENTEX-72
1X
HORNET2-MD-13
2X
M4 x 16
2X
L06-01
1X
HORNET2-MD-10
1X
LOCTITE 234 (THREADLOCKER)
TO BE APPLIED ON ALL FASTENERS
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COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - FEATURES AND COMPONENT PARTS

OX MOTOR
RED
Winches
OVERVOLTING:
This is a term used more frequently over the last few years, and many of the competition teams now do this to their motors and winch setup.
This is where you apply 24vDC power to a 12vDC rated motor. This is known as "Overvolting".
The OX Motor can be "Overvolted", but it comes with warnings, as shown below:
The manufacture does not recommend doing this, as it puts extra load and speed into the motor it was not designed for.
"Overvolted" motors are not covered by any warranty, claims for motor damage can be investigated but not supported in competition use.
"Overvolted" motors must be maintained and serviced regularly, at least every 3 Events.
"Overvolted" motors must not be run continuously under no load conditions (winding rope in or our), the longer they are run the faster they will go,
too fast and they can go above 20,000rpm and mechanical damage will occur at this speed. When little or no load is on the motors, always operate
the motors in short bursts. Bursts can be 10-15m or rope a time onto the drum.
"Overvolted" motors still draw the same AMPS as non-overvolted motors. 12v on 12v = 24v on 12v, some people think the AMPS are halved, they are not.
Your winch can draw 900A in an extreme pull with a twin motor setup. So be warned, make sure all the electrical elements in your winch system can
support and cope with this level of AMP draw.
BUILD FEATURES:
Twin bearing setup (Front and Back)
•
Heavy duty brush pack, for those that want to over-volt
•
Dedicated mounting holes on the rear of the motor end plate for your motor solenoid
•
Flat rear cover, allowing mounting of the motor solenoid easier
•
High quality, robust commutator and brush setup
•
More efficient design, transfering the power with reduced losses
•
Voltage: 12v
•
Power: 7hp
•
No Load Speed: 11,800rpm
•
Max Amp Draw: 438A
•
Real World Testing Results
•
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TYPE
DESCRIPTION:
RED
Winches
WORKSHOP MANUAL
ULTIMATE PERFORMANCE WINCH
OX MOTOR
ULTIMATE COMPETITION MOTOR

238
151
171.50
BRUSH PACK
IN FRONT OF MOTOR
M8 THREAD
EARTH CONNECTIONS
3 OPTIONS FOR POSITION
POSITIVE
CONNECTION
FROM BATTERY
VIA ISOLATOR
12V or 24V DC
O-RING IN END PLATE
F1
F2
A
116.00
10
8
2
3
2
6
7
9
1
OX MOTOR
SUPPLIED IN:
12V - BUILD
24V - BUILD
4
5
DRAWING SHOWS OX MOTOR
WITH WINCH OPERATIONAL
PARTS FITTED:
ALBRIGHT: 1000 SERIES
•
COPPER BUS BARS
•
BUS BAR COVER
•
MOUNTING BOLTS
•
ITEM NO.
PART / DRG
NUMBER
DESCRIPTION
ALBRIGHT-COVERS-
BUSBARS/QTY.
1
RWM-MD-10
ELECTRIC MOTOR PULL SHAFT
2
2
RWM-MD-12
SHORT BUZZ BAR - OX MOTOR
2
3
RWM-MD-15
BUS BAR COVER - OX MOTOR
1
4
RWM-MD-13-1
ARMATURE BUZZ BAR - OX MOTOR
1
5
RWM-MD-14
BRASS POWER ROD - M8
1
6
M8
HEXAGON FULL NUT
9
7
M8 FORM A
WASHER
9
8
DC0088-1000P
DC88 ALBRIGHT SOLENOID
1
9
M8 x 12
M8 x 12 GRUB SCREW
2
10
M6 x 16
M6 x 16 SKT CP HEAD
2
11
RWM-MD-20 GP100 ADAPTER RING
1
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RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
RED WINCH COBRA 2 - FEATURES AND COMPONENT PARTS

Lubrication Details
Grease Specification: Gearbox
Castrol Spherol L-EP 2 or BP Energrease LS-EP 2
Grease Specification: Freespool Shaft
Duck Oil for internal Piston
Copper Grease for External Spline
As a guide Grease must be applied to the gears in the end housing and air
freespool clutch plate as per the following:
The lubrication frequency is based on constant 100% actual winch
usage in hours per month:
1-12 Hrs - Add grease and cover gears every 6 Months
12-24 Hrs - Add grease and cover gears every 4 Months
This is based on dry above water level conditions.
If winch has been used within water or wet muddy ground for more than 50% of the
hours specified the greasing frequency needs to be increased to half of those times
shown in the above chart.
Every 12 months the internals of the winch gearbox and freespool should be
cleaned and the grease should be replaced.
Important:
Freespool must be cleaned and internal parts sprayed with duck oil
after the winch has been submerged in mud or water for long periods of time or
stood standing for several weeks. The gearbox must also be inspected for water
ingress and greased if necessary.
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RED
Winches
COBRA-MANUAL
ULTIMATE PERFORMANCE PRODUCTS
COBRA 2 - GREASE SHEET

This winch is part of a range of winches that are designed for high speed
and high power. This winch will pull rope onto its drum quickly and with
power. If operated without care and attention this winch could easily
damage fingers, hands and in some cases eyesight.
The winch is powered by DC voltage, in most cases 12v, but also 24v
systems can be used to power the winch. The current draw on this DC
voltage can be high so care and attention must be taken when operating
the winch that the electrical power to the motors is not exposed to the
operator.
The winch should only be operated by a person who has been authorised
to do so or has been trained to operate it safely.
Safety on the Winch
Safety Instructions - COBRA 2 Winch
The Winch
Set-up Procedure
The winch is an excellent choice when it comes to speed and power for
electric winching. It has been designed specifically for high performance
and durability.
The winch body is CNC machined from high grade heat treated aerospace
aluminium from solid billets. Its patented brake system offers something
previously unavailable on a winch and ensures the winch stops instantly
when your finger it taken off the winch control button.
Springs apply pressure to a steel disc which then applies pressure to the brake disc and its
material when the winch is not in use. This applies the brake and stops the winch drum
from moving under load and from spooling out the rope.
An air solenoid for the air brake is fitted next to the motors at the top of the winch.
This is fed by an air supply from the ARB compressor.
When you winch in or out you energise your Albright motor solenoids this also energises
the air solenoid valve for the brake on top of the winch.
This then allows air to go into a specially designed chamber that releases the brake
instantly.
When you remove your winching finger from the controls the air solenoid dumps the air
and the springs apply the brake disc onto the brake pads.
This means compared to normal winching you do not get overrun or excess rope causing
snatching and jerking as the vehicle takes up the slack rope that has been spooled out. This
design has been submitted for full patent and is currently protected and patent pending.
The electrical power of this winch is currently supplied by a single OX Motor, 12v (7HP).
This is supplied normally with a 12v supply from your vehicle onto the high efficiency
copper busbar assembly found on top of the motors.
The high power Albright motor solenoids are used to switch direction of the motors and at
the same time provide a feed to the 12v brake system via their signal terminals.
The winch air brake system:
The drum is mechanically driven by a solid steel hardened clutch plate.
This is a very tough hardened plate.
The clutch plate is driven from the gearbox by a solid steel central shaft passing through the
middle of the drum. The drive system has been built for strength and durability.
All our winches are now supplied with Plasma Locks to hold the synthetic rope onto the
drum, proven method and very reliable.
It is a nice simple solution to ensure you always have the minimum amount of line wraps on
your winch drum.
With the Plasma Lock installed you can pull your rope line out with confidence that it won't
leave you without any line on the drum!
The Plasma lock has been designed for a variety of line gauges and you can feel confident
that at least 8-10 wraps remain on your drum, reducing greatly the chances of a slippage.
The Plasma Lock is made from double thickness, heavy duty bright red webbing and is
150mm x 40mm (approx).
Drum
The gearbox has been specifically designed for strength, power and
ease of service. All gears are manufactured from 655-M13 nickel
chromium molybdenum steel and case hardened to give maximum
strength (1100 N/mm²) and excellent durability. The end covers are
sealed via an o-ring and groove, ensuring a watertight seal. Once the
cover is removed access to all gears is possible and only takes a short
time to service and re-assemble.
The gearbox runs in grease not oil making it much easier to service in
the field.
Gearbox
WARNING! THIS WINCH IS ONLY SUITABLE FOR WINCHING SITUATIONS /
APPLICATIONS
WARNING! Ensure all fasteners and connections are adequately connected or
secured before using the winch
Maintain the equipment in good condition (use an authorised servicing agent if
required)
Replace or repair damaged parts. Use genuine parts only. Unauthorised parts
may be dangerous and will invalidate any warranty.
Use a qualified person to lubricate if required and maintain the equipment.
Before use, ensure all parts are clean and free of contamination / dirt.
DO NOT use solvent cleaners to clean this winch
Use the equipment in a suitable work or operational area, keep winching area
clean and tidy and free from unrelated materials, and ensure that there is
adequate lighting while setting and operating the winch.
Keep the winch and winch rope clean for best and safest performance.
The maximum line load is 4500kg. DO NOT exceed this rated capacity.
When operating remove ill-fitting clothing. Remove ties, watches, rings and
other loose jewellery, and contain long hair.
Maintain correct balance and footing, do not over reach. Ensure the floor /
ground is not slippery and wear appropriate footwear.
Before using the winch check that there are no overhead or surrounding
obstructions.
The speed during operation must be kept steady and constant. Do not
generate sudden movements or shock loads.
DO NOT use the winch for a task it is not designed to perform.
DO NOT use the equipment if damaged.
DO NOT exceed the rated capacity of the equipment.
DO NOT use the equipment when you are tired or under the influence of
alcohol, drugs or intoxicating medication.
DO NOT allow untrained persons to use the equipment unsupervised
DO NOT attempt to transport a load outside JLR designated safe load / unload
areas.
DO NOT make any modifications to the equipment
DO NOT operate the winch and handle the synthetic rope without approved
winching gloves and appropriate PSE
(1) Check winch as per the safety instructions
(2) Check winch is situated correctly for the task at hand
(3) Check rope is on drum securely and is not tangled
(4) Check Hook condition and clasp is good and working correctly
(5) Switch Compressor on
(6) Connect power to winch via isolator
(7) Winch is now ready to operate
The winch can release and winch line at speed, faster than a normal
single motor winch.
The winch gearbox has gears that are straight cut for strength and
durability
The compressor will run and vibrate whenever it needs to top up the
air in the system.
This compressor could start when the winch is not being operated if
the air pressure in the system drops
Startup
Q: How do I store the rope on the drum?
A: Always leave the drum and rope neatly spooled after use with the
rope clean and evenly layered
Q: What should I do if the winch has been used in muddy / wet /
dirty conditions
A: After a prolonged dirty wet operation clean and wash the rope
and clean all connections
Q: What if the winch stops while operating?
A: If the winch overloads, i.e. it stops under load, release the control
button immediately and assess the situation otherwise you could
damage the motors. Check all electrical connections to ensure they
are secure and look normal. Check battery condition before
continuing to winch.
Q & A

DESCRIPTION
COMPLETED
YES / NO
NOTES
ALL BOLTS AND SCREWS FITTED CORRECTLY
ALL BOLTS AND SCREWS (APART FROM THOSE INDICATED) SECURED
WITH LOCTITE 234
ALL BOLTS AND SCREWS FITTED CORRECTLY AND TIGHTENED TO THE
CORRECT TORQUE SETTING
GEARS FULLY GREASED AND MINIMUM OF 1" OF GREASE IN LOWER PART
OF GEARBOX CASE
MOTORS CHECKED FOR FUNCTION & QUALITY
FREESPOOL ON DRUM IS FREE AND EASY TO TURN
AIR FREESPOOL CONNECTION CHECKED FOR LEAKS
AIR FREESPOOL GREASED ON SPLINE AND DISC.
DUCK OIL APPLIED INTERNALLY ON O-RINGS AND PISTON.
AIR FREESPOOL FUNCTION TESTED AT LEAST 20 TIMES.
TO WORK EVERY TIME.
CORRECT BOLT LENGTHS HAVE BEEN USED ADN ALL MOUNTING HOLES
ARE CLEAN AND FREE FROM DIRT
WINCH POWERED AND TESTED IN BOTH DIRECTIONS. AIR FREESPOOL
AND BRAKE SOLENOID CHECKED TO ENSURE CORRECT OPERATION.
NAME OF ENGINEER
BUILT / PERFORMED
FINAL CHECKS
SIGNATURE
WINCH SERIAL NUMBER
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PUMP
TYPE
PUMP
DESCRIPTION:
RED
Winches
COBRA XL WINCH
ULTIMATE PERFORMANCE WINCH
COBRA 2
INSPECTION SHEET
ELECTRIC LOW LINE WINCH
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