Red Winches Cobra 2 User manual

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Cobra 2
HIGH MOUNT |ELECTRIC WINCH
COBRA 2
MANUAL
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Contents
Winch Dimensions .......................p8
Winch Overview Diagram ...............p10
Winch Exploded Diagram ................p11
Winch Pulley Arrangement .............p12
Winch Freespool Diagram ..............p13
Wiring Connection Schematic ..........p14
Ox Motor Diagram ......................p15
Brake Assembly.........................p16
Standard Gear Box Diagram ............p17

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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.
STANDARD GEAR BOX DIAGRAM 11.
RED WINCH COBRA 2 STANDARD GEARBOX - TECHNICAL MANUAL
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TITLE
RED Winches
CONTENTS
ULTIMATE PERFORMANCE PRODUCTS
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.
STANDARD GEAR BOX DIAGRAM 11.
RED WINCH COBRA 2 STANDARD GEARBOX - TECHNICAL MANUAL
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TITLE
RED Winches
CONTENTS
ULTIMATE PERFORMANCE PRODUCTS
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.
STANDARD GEAR BOX DIAGRAM 11.
RED WINCH COBRA 2 STANDARD GEARBOX - TECHNICAL MANUAL
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TITLE
RED Winches
CONTENTS
ULTIMATE PERFORMANCE PRODUCTS
>Low line
>Single motor
>12v / 24v dc
>Air brake fitted on all options
>Freespool (Options of Manual or Air Operated)
>Standard and XL Drum lengths available
>Gearboxes Available: Standard, Adventure, Titan
>Rated pulls: From 2,000kg - 6,000kg (model specific)
>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 solid billet
machined cnc housings make it an ideal winch for maximum impact when faced with
minimal installation space.
Cobra 2
HIGH MOUNT | ELECTRIC WINCH

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>The Winch
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 can give you great speeds
combine dwith strong pullign power giving you the
end user options for your recovery needs, so you have
power and speed when you need it.
The winch body is CNC machined from solid high grade
heat treated aerospace aluminium. Its brake system
oers something previously unavailable on a winch and
ensures the winch stops instantly when your finger is
taken o the winch control button.
>RED Winch Air Brake System
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 onboard compressor.
When you winch in or out you energise your motor
solenoid, 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 of excess rope causing snatching and
jerking as the vehicle takes up the slack rope that has
been spooled out. It also means when spoolign the rope
back onto the drum and you stop winching, the rope
stops and doesnt continue spooling in. A safety feature
many find important when looking after the operators
hands.
The high power Albright motor solenoid is used to
switch direction of the motor and at the same time
provide a feed to the 12v brake system via their signal
terminals.
>Gearbox
The gearbox has been specifically designed for
strength, power and ease of service.
All gears are manufactured from chromium
molybdenum steel and case hardened to give maximum
strength (Up to 1230 N/mm2) and excellent durability.
The gearbox runs in grease not oil making it much
easier to service in the field.
Cobra 2
>Simple Set-Up Procedure
1Check winch connections are correctly fitted
and are not loose
2Switch winch isolator on
3Switch Compressor on
4Connect Wireless Controller with base unit
(if used)
5Winch is now ready to be used

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SYMBOL EXPLANATION
Read all product literature
Always wear leather gloves
Always wear hearing & eye protection
Fairlead pinch point
Always use supplied hook strap
Properly seat load in throat hook
Never apply load to hook tip or latch
Never hook back on rope
SYMBOL EXPLANATION
Explosion/Bursting Hazard
Fire and burn hazard
Never route electrical cables across sharp
edges
Never route electrical cables through or
near moving parts
Avoid installing electrical cables around
pinch and wear/abrasion points
Never use inch as a hoist
Do not move people
Wind rope on bottom of drum
SYMBOL EXPLANATION
Never wind rope over top drum
Hand piercing/cutting hazard
Hot surface hazard
Finger/Fairlead crushing Hazard
Exposed wiring hazard insulate exposed
wiring and terminals
Clutch disengaged
Avoid side pulls
Never hook the wire rope back onto itself
Every winching / recovery situation has the potential
for personal injury. In order to minimize that risk, it
is important to read this guide carefully before using
the winch.
Please familiarize yourself with the operation of your
winch before using it and be constantly safety oriented.
In this guide we provide important safety information
and instructions on how to install your winch.
SAVE THIS MANUAL and other product literature
found in this kit for future reference and review
frequently for continuing safe operation.
Instruct all users of this winch product to review this
manual before operating the winch.
>Symbol Index for winch
SAFETY GUIDELINES

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>WARNING >WARNING
>Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to serious injury or death.
Winching Safety:
• Always Know Your Winch. Take time to fully read the Instructions
in Order to understand your winch and its operations.
• Never exceed winch or winch rope rated capacity. Double line
using a snatch block to reduce winch load.
• Always wear heavy leather or approved gloves when handling
winch rope.
• Never use winch or winch rope for towing. Shock loads can
damage, overload and break rope.
• Never use a winch to secure a load.
• Never operate this winch when under the influence of drugs,
alcohol or medication
• Never operate this winch if you are under 16 years of age.
Installation Safety:
• Always choose a mounting location that is suciently strong to
withstand the maximum pulling capacity of your winch.
• Always use class 8.8 metric( grade 5) or better fasteners
• Never weld mounting bolts.
• Always use factory approved mounting hardware, components,
and accessories.
• Never use bolts that are too long.
• Always confirm required bolt length to ensure proper thread
engagement.
• Always complete the winch installation and hook attachment
before installing the wiring.
• Always keep hands clear of winch rope, hook loop, hook and
fairlead opening during installation, operation, and when
spooling in or out.
• Always position fairlead slot so rope does not rub on it during
normal straight line recovery operations.
• Always prestretch rope and respool under load before use.
Tightly wound rope reduces chances of ‘binding’, which can
damage the rope.
>Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to serious injury or death.
General Safety:
• Always inspect winch rope, hook, and slings before operating
winch. Frayed, kinked or damaged winch rope must be replaced
immediately. Damaged components must be replaced before
operation. Protect parts from damage.
• Always remove any element or obstacle that may interfere with
safe operation of the winch.
• Always be certain the anchor you select will withstand the load
and the strap or chain will not slip.
• Always use supplied hook or spliced loop whenever spooling
winch rope in or out, during installation and during operation.
• Always require operators and bystanders to be aware of vehicle
and or load.
• Always be aware of stability of vehicle and load during winching,
keep others away. Alert all bystanders of an unstable condition.
• Always unspool as much winch rope as possible when rigging.
Double line or pick distant anchor point.
• Always take time to use appropriate rigging techniques for a
winch pull.
• Never touch winch rope or hook while someone else is at the
control switch or during winching operation.
• Never engage or disengage freespool lever if winch is under
load, the rope line is securing an object, winch rope is in tension
or drum is moving.
• Never touch winch rope or hook while under tension or
under load.
• Always stand clear of winch rope and load and keep others away
while winching.
• Never use vehicle to pull load on winch rope. Combined load or
shock load can damage, over load and break rope and winch.
• Never wrap winch rope back onto itself. Use a choker chain or
tree trunk protector on the anchor.
• Never use remote when vehicle is not in line of sight of operator.
• Never pair more than one winch and one remote
together at the same time.
>Warnings and Cautions
As you read these instructions, you will see WARNINGS,
CAUTIONS, NOTICES and NOTES.
Each message has a specific Purpose. WARNINGS are safety
messages that indicate a potentially hazardous situation, which, if
not avoided could result in serious injury or death. CAUTIONS are
safety messages that indicate a potentially hazardous situation,
which, if not avoided, could result in minor or moderate injury.
A CAUTION may also be used to alert against unsafe practice.
CAUTIONS and WARNINGS identify the hazard, indicate how to
avoid the hazard, and advise of the probable consequence of not
avoiding the hazard. NOTICES are messages to avoid property
damage. NOTES are additional information to help you complete a
procedure. PLEASE WORK SAFELY!
>EMC Regulation
This device complies EMC regulations. Operation is subject to the
following two conditions:
• This device may not cause harmful interference.
• This device must accept any interference received, including
interference that may cause undesired operation.
This equipment has been tested and found to comply. See
seperate CE certificate. These approvals are designed to provide
reasonable protection against harmful interference in a residential
installation. This equipment generates, uses and can radiate radio
frequency energy, and if not installed and used in accordance
with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference
will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which
can be determined by turning the equipment o and on, the user is
encouraged to try to correct the interference by one or more of the
following measures:
• Reorient or relocate the receiving antenna (if installed)
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit dierent from
that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.

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>WARNING >WARNING >CAUTION
>NOTICE
>NOTICE
>WARNING >CAUTION
>WARNING
>Falling Or Crushing Hazard
Failure to observe these instructions could lead to serious injury or death.
• Always stand clear, keep hands clear, keep others away.
• Never operate winch with less than 6 wraps of synthetic rope
around the drum. Rope could come loose from the drum, as the
rope attachment to the drum is not designed to hold a load.
• Never use winch as a hoist or to suspend a load, its a winch not
a hoist.
• Always be certain anchor will withstand load, use appropriate
rigging and take time to rig correctly.
• Never use winch to lift or move people.
• Never use excessive eort to free spool winch rope.
• Always use proper posture/lifting technique or get lifting
assistance while handling and installing product.
• Always wind the winch rope on bottom (mount side) of drum.
• Never wind rope over top of drum.
• Always spool the winch rope onto the drum in the direction
specified by the drum rotation labels on the winch and/or in the
documentation. This is required for the automatic brake (if so
equipped )to function properly.
>Cut And Burn Hazard
Failure to observe these instructions could lead to minor or moderate
injury.
• Never let winch rope slip through your hands. Alwasy use
recomended gloves / hand protection.
>Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to serious injury or death.
To avoid injury to hands and fingers:
• Never leave winch remote control where it can be activated
during free spooling, rigging, or when the winch is not being used.
• Never leave the wireless winch remote control turned on or
connected to winch controls when installing, free spooling,
rigging or servicing winch, or when the winch is not being used.
AVOID WINCH AND EQUIPMENT DAMAGE
• Always avoid side pulls which can pile up winch rope at one end
of the drum, this can damage winch rope or winch.
• Always ensure the freespool is fully engaged or disengaged.
• Always use care to not damage the vehicle frame when
anchoring to a vehicle during a winching operation.
• Never submerge winch in water, if not IP68 rated.
• Always store the remote control in a protected, clean dry area.
• Never hook the synthetic rope back onto itself because you
could damage the synthetic rope .Use a strap.
• Avoid continuous pulls from extreme angles as this will cause the
rope to pile up on one end of the drum. This can jam the rope
and casue the rope to dive down through other rope layers.
This manual provides instructions on how to install and operate your winch and operating your Wireless Remote Control.
When installing your winch system, read and follow all mounting and safety instructions. Always use caution when working with electricity and
remember to verify that no exposed electrical connections cn accidently be touched before energizing your winch circuit. For specifications
and performance data, refer to the specification sheets and the RED Winches website.
>Chemical And Fire Hazard
Failure to observe these instructions could lead to serious injury or death.
• Always remove loose jewellery and wear eye protection.
• Never route electrical cables across sharp edges.
• Never route electrical cables near parts that get hot.
• Never route electrical cables through or near moving parts.
• Always place the supplied terminal boots on wires and terminals
as directed by the installation instructions.
• Never lean over battery while making connections.
• Never route electrical cables over battery terminals. Never short
batter terminals with metal objects.
• Always consult operator’s manual for proper wiring details.
• Always insulate and protect all exposed wiring and electrical
terminals.
• Always connect red(+) power cable ONLY to the positive(+)
terminal of the battery.
• Always connect black ground(-) power cable ONLY to the
negative(-)terminal of the battery.
• Never connect red(+) power cable to the negative(-) terminal of
the battery.
>Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to serious injury or death.
• Always ensure hook latch is closed and not supporting load
• Never apply load to hook tip or latch. Apply load only to the
centre of hook.
• Never use a hook whose throat opening has increased, or whose
tip is bent or twisted.
• Always use a hook with a latch.
• Always ensure the operator and bystanders are aware of the
stability of the vehicle and/or load. Never hook back on rope.

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(XL)
(XL)
(XL)
Cobra 2
>Overdrive & Standard Model Shown
>Standard Drum Width
For the XL Drum versions, the dimensions marked with (XL)
will increase by 76mm (3”)

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(XL)
(XL)
(XL)
Cobra 2
>Adventure & Titan Model Shown
>Standard Drum Width
For the XL Drum versions, the dimensions marked with (XL)
will increase by 76mm (3”)

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ULTIMATE BRAKE FOR
YOUR WINCH
AIR BRAKE ASSEMBLY
FITTED TO END OF GEARBOX
ALBRIGHT MOTOR CONTROLLER
AIR SOLENOID FOR AIR BRAKE
6MM AIRLINE TUBE REQUIRED
TO FEED PISTON BODY FROM COMPRESSOR
VIA A TOGGLE OR SOLENOID SWITCH
(IF AIR FREESPOOL ORDERED / FITTED)
AIR FREESPOOL SHOWN
ROTATED BACKWARDS AT 1PM POSTION
MANUAL FREEESPOOL OPTION FITTED
AT 11AM CLOCK POSITION, FORWARD
COVER CAN BE
REMOVED EASILY TO
SERVICE THE PULLEYS
AND BELTS INSIDE
PRECISION ENGINEERED
BILLET MACHINED HOUSINGS
AND DRUM ENDS, THE ULTIMATE
IN STRENGTH AND DESIGN
HAWSE FAIRLEAD
ALUMINIUM - CNC MACHINED
WITH LARGE RADIUS TO
EXTEND ROPE LIFE
ENGINEERED DRUM
SUPPORTED BY PRECISION
SEALED BEARINGS
ADDED PROTECTION
FROM 2 x DRUM END SEALS
THE MIGHTY OX MOTOR IS A
VERY POWERFUL MOTOR
PROVIDING HIGH SPEED
AND HIGH TORQUE FOR
ALL WINCHING SITUATIONS
COPPER BUS BARS
FOR THE ULTIMATE
TRANSFER OF POWER

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ITEM 17 - MOUNTING BOLTS
M16 X 12 CAP HEADS AR FITTED FOR OUR ASSY PROCESS ONLY.
THESE BOLTS ARE TO BE REMOVED PRIOR TO INSTALLATION
>MAIN WINCH BODY
FASTENERS
ENSURE ALL FASTENERS ARE TORQUED TO THE CORRECT
VALUES. LOCTITE 234 (THREADLOCK) TO BE APPLIED ON
ALL FASTENERS
UNLESS SPECIFIED
FASTENER TORQUE
M6 10 Nm
M8 24 Nm
M10 45 Nm
M12 80 Nm
M16 160 Nm
M20 200 Nm
Cobra 2 >Exploded Diagram

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AIR BRAKE HOUSING
6MM AIR PIPE
90DEG FITTING
BREATHER
PISTON BODY
PISTON SEALING CAP
BRAKE REACTION
PLATE LOWER
PISTON O-RING
PISTON SEALING CAP
O-RING
PISTON SEALING CAP
CIRCLIP
BRAKE REACTION
PLATE UPPER
BRAKE DISC
BRAKE PAD
LOWER
BRASS DRIVE
PINS
BRAKE PAD
UPPER
REACTION PLATE
PILLARS
GUIDE BEARING
BRAKE
SPRINGS
>AIR BRAKE
FASTENERS
ENSURE ALL FASTENERS ARE TORQUED TO THE CORRECT
VALUES. LOCTITE 234 (THREADLOCK) TO BE APPLIED ON
ALL FASTENERS
UNLESS SPECIFIED
FASTENER TORQUE
M6 10 Nm
M8 24 Nm
M10 45 Nm
M12 80 Nm
M16 160 Nm
M20 200 Nm

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DRIVE
BELT
COVER REMOVED FOR CLARITY
TOP PULLEY
LOWER PULLEY

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A
A
PIN HOLDS PISTON
IN PLACE
6MM TUBE REQUIRED
FROM AIR SOLENOID
OR TOGGLE SWITCH
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:
REMOVE POWER, AIR EXHAUSTS, PIN RE-ENGAGES
AIR FREESPOOL ASSEMBLY (SHOWN)
DRUM FREESPOOL:
SWITCH OPERATED OR WIRELESS
AIR SUPPLIED THROUGH A 2-WAY DC SOELNOID VALVE
DRUM FREESPOOL:
LIFT AND ROTATE TO
INITIATE DRUM FREESPOOL MOVEMENT
MANUAL FREESPOOL ASSEMBLY (NOT SHOWN)
ENGAGE DRUM:
ROTATE AND LOWER
RED WINCH COBRA 2 STANDARD GEARBOX - TECHNICAL MANUAL
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TITLE
RED Winches
WINCH FREESPOOL DIAGRAM
ULTIMATE PERFORMANCE PRODUCTS
Manual Freespool Assembly
(Not Shown)
Drum freespool:
Lift and rotate to Initiate drum freespool
movement
Engage drum:
Rotate and lower
Air Freespool Assembly
(Shown)
Drum freespool:
Switch operated or wireless
Air supplied through a 2-way dc soelnoid valve
Engage drum:
Remove power, air exhausts, pin re-engages
PIN HOLDS PISTON
IN PLACE
6MM TUBE REQUIRED
FROM AIR SOLENOID
OR TOGGLE SWITCH

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>Connection Schematic
WINCH IN 12V
SUPPLY FROM
ROCKER SWITCH
ON YOUR DASH
WINCH OUT 12V
SUPPLY FROM
ROCKER SWITCH
ON YOUR DASH
DRUM FREESPOOL
AIR OPERATED OR
MANUAL OPERATED
OPTION AVAILABLE
(AIR SHOWN)
Ø6mm AIRLINE FROM
ONBOARD TRUCK SYSTEM
NEEDS TO BE CONNECTED
HERE COMPACT ARB OR
EQUIVILENT COMPRESSOR MIN
AIR PRESSURE 4.5 BAR (60 PSI)
POSITIVE 12V CABLE
FROM BATTERY TO BE
CONNECTED HERE
M8 MALE THREAD
70mm2 CABLE TO BE USED
WARNING
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
AIR BRAKE
SOLENOID
(SUPPLIED FITTED)
OX MOTOR
12v OR 24V
OPTIONS
AIR BRAKE LINE Ø6mm
(SUPPLIED FITTED)
GEARBOX
HOUSING
EARTH / NEGATIVE
CONENCTION
WINCH
CONTROL
CABLE
AIR BRAKE
FITTED AS STANDARD
+12V SIGNAL WIRES TO
CONNECT TO YOUR
VEHICLE. +12V SIGNAL TO
RED WIRE WILL
WINCH IN, +12V TO BROWN
WIRE WILL WIND OUT.
BLACK IS EARTH / NEGATIVE

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F1 (M8)
BRUSH PACK AT
THE FRONT OF THE
MOTOR HERE
F2 (M8)
A (M8)
BUS BAR COVER
“A”
BAR
EARTH CONNECTION
FROM BATTERY CAN GO
ON EITHER ONE OF THREE
M8 THREADED HOLES
70mm2 CABLE TO BE USED
WiTH THE APPROPRIATE ALTERNATOR AND BATTERY SETUP THESE OX MOTORS WILL PROVIDE HIGH SPPED AND HIGH POWER FOR YOUR WINCH.
POSITIVE +12V CABLE
FROM BATTERY TO BE
CONNECTED HERE
M8 MALE THREAD
70mm2 CABLE TO BE USED
SOLID COPPER BUS BARS
TRASNFER ALL THE POWER
EFFICIENTLY TO THE MOTOR
SMALL ZIP TIE USED
TO HOLD COVER IN PLACE
WARNING
IF OVERVOLTING
(24v POWER ONTO A 12v RATED MOTOR)
NEVER ALLOW THE OX MOTOR TO ‘OVER SPEED’ OR RUN WHEN THE
WINCH IS NOT UNDER LOAD OR HAVE TENSION / WEIGHT IN THE
WINCH LINE. THIS SITUATION CAN DAMAGE THE ARMATURE AND CAUSE
THE MOTOR TO FAIL
AIR SOLENOID FOR
AIR BRAKE. SUPPLIED FITTED
AUTOMATICALLY WORKS
WITH ‘WINCH IN’ OR ‘WINCH
OUT’ +12V SIGNAL FROM
YOUR VEHICLE
DIODE FOR AIR
SOLENOID BI-DIRECTION
OPERATION FITTED IN CAP

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Cobra 2 >Gearboxes
>ADVENTURE / TITAN GEARBOX >STANDARD / OVERDRIVE GEARBOX
RING GEAR
RING GEAR

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These notes are general guidelines only.
Always refer to the Manufacturers Handbook or
contact an Authorised Dealer
GENERAL WINCH MAINTENANCE
>General Maintenance
• Check the battery regularly. Ensure that it is in good
condition and is fully charged.
• Check that all of the connections are clean and tight.
Corrosion on the battery connections can aect the
performance of the winch. Ensure that the battery
connections are tight.
• The winch is protected from water and rain, but
avoid submerging the winch for a prolonged time,
particularly if the winch casing is warm / hot.
• If it does become submerged, once clear, run the
winch in and out for about 10 meters of rope to
generate heat inside the winch to help dry the inside
of the casing.
• Only clean your winch with soap and water, then rinse.
DO NOT PRESSURE WASH THE WINCH. This can
force water past the seals and gaskets.
• If you were not the last person to use the winch,
always inspect the full length of the winch rope before
applying any load to it.
• Have the winch serviced regularly at an authorised
RED Winch centre / Partner / Distributor. (Refer to
manufacturers’ handbook).
>Basic Trouble Shooting
Powers in only one direction
• Faulty Solenoid, damaged remote control or remote
control cable. Check remote control plug pins for
damage. Check remote correctly connected.
Completely Dead
• Burned motor, poor earth, discharged battery, faulty
isolator switch, damaged earth wire, damaged remote
control cable or switch. Check remote control pins for
damage. Check isolator switch is on. Check power is
getting to the winch.
Low Power
• Check the condition of the battery and alternator,
check the voltage to the battery. Are the battery
terminals corroded or the cables damaged?
• Turn o any electrical items in the vehicle; Radio,
lights, heated seats etc.
Winch Will Not Free Spool
• Warped mount plate, winch rope bound up on one
side of the drum, bent drum flange or gear damage
inside the winch.
• Check freespool air solenoid if fitted.
• Check Air solenoid or Air switch s working
• Check freespool knob is free to move and be
disengaged.

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OPERATION OF
YOUR WINCH
A REFERENCE GUIDE
TO WINCHING

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WINCH HANDLING
>Estimating Winch Loads
Before attempting to move a rolling load with a winch,
an estimate of the load should be made to ensure
that the safe working load limits of the winch and any
supporting equipment is not exceeded.
If there is a solid resistance that prevents the load from
moving, the winch must not be allowed to operate
in a situation where it is overloaded; the forces and
electrical loading on the vehicle this creates may
become excessive. The load to be recovered must be
able to move as freely as possible. Before winching it
might be necessary to dig out a trapped wheel or dig
away any part of the terrain upon which is resting any
part of the load apart from its wheels.
There are two factors which should be added together
to arrive at a total load:
The maximum inclination of the ground, even if it is only
a short section; for instance a pot hole or a tree root.
On sloping ground a factor has to be allowed for the
gradient as follows:
Divide the gradient angle in degrees by 60, and multiply
that by the load being pulled. Therefore ascending a
30° gradient with a vehicle weighing 2,250 kg would be:
30° / 60 = 0.5 x 2250 = 1125 kg
The pull required to move a vehicle varies depending
upon the type of ground upon which it stands.
The required pull as a percentage of its weight is as
follows;
A 2250kg Vehicle in shallow mud would be:
2250 / 100 x 35 = 788kg
Therefore to calculate the true load when pulling up an
incline, add the previous calculation for the gradient to
the calculation for the ground condition:
Gradient 1125Kg + Ground 788kg = Total estimated
load 1913Kg
Hard Surface 5%
Grass 15%
Wet Sand 15-20%
Soft Dry Sand 25-30%
Shallow Mud 35%
Bog/Marsh where chassis is not grounded 50%