rough country PRO9500 User manual

SAFETY PRECAUTIONS
Observe safety precautions for personal safety and the safety of others. Improper equipment
operation may result in injury and equipment damage.
Read the following carefully before attempting to operate your winch and keep the instructions for future ref-
erence.
1. Dress Properly:
Don't wear loose clothing or jewelry. They can be caught in moving parts.
Wear leather gloves when handling winch cable. Do not handle cable with bare hands as broken wires can
cause injuries.
Non-skid footwear-is recommended.
Wear protective hair covering to contain long hair.
2.Keep a Safe Distance:
Ensure that all persons stand well clear of winch cable and load during winch operation. 1.5 times the cable
length is recommended. If a cable pulls loose or breaks under load it can lash back and cause serious personal
injury or death.
Don't step over the cable.
All visitors and onlookers should be kept away from the work area.
Keep proper footing and balance at all times.
3.Don't Abuse the Cord:
Never carry your winch by the cord or yank it to disconnect it from the receptacle.
Keep cord from heat, oil and sharp edges.
4.Don't Overwork the winch:
If the motor becomes uncomfortably hot to touch, stop and let it cool for a few minutes.
Don't maintain power to the winch if the motor stalls.
Don't exceed maximum line pull ratings shown in tables. Shock loads must not exceed these ratings.
5.Avoid Unintentional Starting:
Winch clutch should be disengaged when not in use and fully engaged when in use.
6.Check Damaged Parts:
Before using, you should check your winch carefully. Any part that is damaged should be properly repaired
or replaced by an authorized service center.
7.Repair Your Winch:
When repairing, use only identical replacement parts or it may cause considerable danger for the user.
8.Re-spool the Cable:
Leather gloves must be worn while re-spooling. To re-spool correctly, it is necessary to keep a slight load on
the cable. Hold the cable with one hand and the remote control switch with the other. Start as far back and
in the center as you can. Walk up keeping load on the cable as the winch is powered in.
Do not allow the cable to slip through your hand and do not approach the winch too closely.
Turn off the winch and repeat the procedure until all the cable except 1m is in.
Disconnect the remote control switch and finish spooling in cable by rotating the drum by hand with clutch
disengaged.
On hidden winches, spool in cable under power but keep hands clear.
The use of any other accessory or attachment other than those recommended in the instruction
manual may present a risk of personal injury.

WINCH OPERATION WARNINGS
Read the following carefully before attempting to operate your winch and keep the instructions for future
reference.
The uneven spooling of cable, while pulling a load, is not a problem unless there is a cable pile up on one end
of the drum. If this happens reverse the winch to relieve the load and move your anchor point further to the cen-
ter of the vehicle After the job is done, you can un-spool and rewind for a neat lay of the cable.
Store the remote control switch inside your vehicle where it will not become damaged, inspecting it before you
plug it in.
When ready to begin spooling in, plug in remote control switch with clutch disengaged. Do not engage clutch
with motor running.
Never connect the hook back to the cable. This causes cable damage. Always use a sling or chain of suitable
strength.
Observe your winch while winching, while standing at a safe distance. Stop the winching process every 3 to 4
feet to assure the cable is not pulling up in one corner. Jamming the cable can break your winch.
Do not attach tow hooks to winch mounting apparatus. They must be attached to vehicle frame.
The use of a snatch block will aid recovery operations by providing a doubling of the winch capacity and a
halving of the winching speed, while maintaining a direct line pull to the center of the rollers. When double
loading during stationary winching, the winch hook should be attached to the chassis of the vehicle.
Ensure rated "D" or bow shackles are used in conjunction with an approved tree trunk protector to provide a
safe anchor point.
When extending winch cable, ensure that at least five wraps of cable remain on drum at all times. Failure to do
this could result in the cable parting from the drum under load. Serious personal injury or property damage
may result.
All winches are provided with a Red Cable marking to identify that the minimum of 5 cable wraps remain on
the Winch drum. When this mark appears at the rollers. No recovery should be attempted beyond this marking.
Since the greatest pulling power is achieved on the innermost layer of your winch, it is desire-able to pull off
as much line as you can for heavy pulls (you must leave at least 5 wraps minimum on the drum - red cable).
If this is not practical use a snatch block and double line arrangement
Draping a heavy blanket or similar object over the extended winch cable is recommended as it will dampen any
back lash should failure occur.
Neat, tight spooling avoids cable binding which is caused when a load is applied and the cable is pinched be-
tween the others. If this happens, alternatively power the winch in and out. Do not attempt to free a bound ca-
ble under load by hand.
Apply blocks to wheels when vehicles are on an incline.

Cont:
Battery:
Be sure that the battery is in good condition. Avoid contact with battery acid or other contaminants.
Always wear eye protection when working around a battery.
Have the engine running when using the winch to avoid damaging the battery.
Winch Cable:
Be sure that the cable is in good condition and is attached properly
Do not use the winch if cable is frayed.
Do not move the vehicle to pull a load.
Do not replace the cable with a cable of lesser strength.
The life of the cable is directly related to the use and care it receives. Following its first and subsequent
uses, a cable must be wound on to the drum under a load of at least 500lbs (230kg) or the outer wraps will
draw into the inner wraps and severely damage the cable during winching. The first winch use should be a
familiarization run while in a relaxed, non-recovery situation. Spool out the cable until the red cable mark
appears (about five wraps on the drum). Rewind the cable on to the drum under a load of 500lbs (230kg) or
more. This will slightly tension and stretch the new cable and create a tight cable wrap around the drum.
Failure to do so may result in cable damage and reduced cable life.
When the cable is replaced, be sure to apply Loc-tite or an equivalent compound to the cable clamp thread.
Tighten the clamp screw but do not over tighten. The Loc-tite will prevent loosening of the screw in haz-
ardous conditions. Loc-tite 7471 Primer and 222 Thread-locker are recommended.
Do not attempt to exceed the pulling limits of this winch.
DO NOT drive your vehicle to assist the winch in any way. Vehicle movement in combination with winch op-
eration may overload the cable and/or the winch and cause damaging shock loads.
Shock loads when winching are dangerous! A shock load occurs when an increased force is suddenly applied
to the cable. A vehicle rolling back on a slack cable may induce a damaging shock load.
The winches shown in this manual are solely for vehicle and boat mounted non-industrial applications.
Do not use winch in hoisting applications due to required hoist safety factors and features.
Do not use the winch to lift, support or otherwise transport personnel.

WINCH OPERATION
SUGGESTION:
The best way to get acquainted with how your winch operates is to make a few test runs before you actually
need to use it. Plan your test in advance. Remember you can hear your winch as well as you can see it operate.
Get to recognize the sound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting.
Soon you will gain confidence in operating your winch and its use will become second nature to you.
OPERATING:
Ensure the vehicle is secure by applying the parking brake or chocking the wheels
Pull out the winch cable the desired length and connect to an anchor point. Be sure to leave 5 full wraps of ca-
ble on the winch drum.
The winch clutch allows rapid uncoiling of the cable for hooking onto the load or anchor point. The shifter tab
located on the gear housing of the winch operates the clutch as follows:
To disengage the clutch, move the clutch shifter tab to the "OUT" position. Cable may not be free spooled off
the drum.
To engage the clutch, move the clutch shifter tab into the "IN" position. The winch is now ready for pulling.
Recheck all cable rigging before proceeding.
Plug in the winch hand control. It is recommended that the winching operation takes place from the driver's po-
sition to ensure safe operation.
To commence winching operation; start vehicle engine, select neutral in transmission and maintain engine
speed at idle.
Operate the remote control switch to IN or OUT until the vehicle has been retrieved. Regularly check the
winch to ensure cable is winding onto the drum evenly.
NOTES:
Never winch with your vehicle in gear or in park, which would damage your vehicle's transmission.
Never wrap the cable around the object and hook onto the cable itself. This can cause damage to the object
being pulled, and kink or fray the cable and result in cable failure.
Keep hands, clothing, hair and jewelry clear of the drum area and cable when winching.
NEVER use the winch if the cable is frayed, kinked or damaged. Replace cable immediately.
Never allow anyone to stand near the cable or in line with the cable behind the winch while it is under power.
If the cable should slip or break, it can suddenly whip back towards the winch, causing a hazard for anyone in
the area. Always stand well to the side while winding.
Don't leave the switch plugged in when winch is not in use.
CHECK THE WINCH CAREFULLY AND THOROUGHLY BEFORE OPERATING!
MAINTENANCE
It is highly recommended that the winch be used regularly (once a month). Simply power the cable out 15m,
free spool 5m and then power back in. This will keep all components in good working condition so that the
winch can be relied on when needed. Contact your authorized Rough Country Recovery Systems outlet for
technical assistance.

ELECTRICAL CONNECTIONS
For normal self-recovery work, your existing electrical system is adequate. A fully charged battery and proper
connections are essential. Run the vehicle engine during winching operations to keep battery charged.
For ease of installation the Rough Country Winch
control box is already wired to the winch body. It is
recommended to check the electrical connections on
the control box and on the body of the winch to ensure
they are tight. DO NOT over-tighten these fasteners.
Simply snug the nuts with a wrench to avoid damage
to the threaded terminals. Install the black ground wire
as shown below and connect to the battery source.
POWER AND GROUND CONNECTIONS
• Long black cable connecting to the bottom terminal
of the motor, and the other end of this terminal con-
necting to negative (-) terminal of battery.
• Long red cable Positive (+) connecting to positive
(+) terminal of battery.
NOTE:
Your battery must be kept in good condition.
Be sure battery cables are not drawn tight across any surfaces, which could possibly damage them.
Corrosion on electrical connections will reduce performance or may cause a short.
Clean all connections especially in remote control switch and receptacle.
In salty environments, use a silicone sealer to protect from corrosion.

Single line rated pull 9500Lb(4300kg)
Motor 5.5HP Series Wound
Control Remote switch, 12ft(3.7m)lead
Gear train 3 Stage Planetary
Gear reduction ratio 265:1
Clutch Sliding Ring Gear
Braking Action Automatic In-The-Drum
Drum size Diameter 2.5"(63.5mm) Length 8.8"(224mm)
Cable 94ft of 5/16" diameter (28m of 8.3mm diameter)
Fairlead 4-Way Roller Fairlead
Remote Control Included
Battery Recommended: 650CCA minimum for winching
PRO9500 FEATURES AND SPECIFICATIONS
LINE SPEED AND AMP DRAW (FIRST LAYER)
Battery Leads 2 gauge, 72"(1.83mm)
Finish Black/Dark Grey
Weight N.W. 84lbs(38kg) G.W. 94lbs(42.5kg)
Overall dimensions (LxWxH) 21.3" x 6.3" x 8.6"(562 x 160 x 218mm)
Mounting Bolt Pattern 10.00*0.015" x 4.50±0.010" (254 x 114.3mm)
Line Pull Lbs 9500
kgs 4300
Line Speed ft/mm 5.2
m/min 1.6
Motor Current amps 340
Layer of cable 1 2 3 4
Rated line pull per layer Lbs 9500 7700 6500 5700
Kgs 4300 3480 2940 2580
Cumulative cable
capacity Lbs 16 42 72 94
Kgs 5 12 21 28

Single line rated pull 12000Lb(5440kg)
Motor 6HP Series Wound
Control Remote switch 12ft{3.7m)lead
PRO12000 FEATURES AND SPECIFICATIONS
LINE SPEED AND AMP DRAW (FIRST LAYER)
Gear train 3 Stage Planetary
Gear reduction ratio 265:1
Clutch Sliding Ring Gear
Braking Action Automatic In-The-Drum
Drum size Diameter 2.52"(64mm) Length 8.82*(224mm)
Cable 94ft o( 3/8' diameter (28m of 9.4mm diameter)
Fairlead 4-Way Roller Fairlead
Remote Control Included
Battery Recommended: 650CCA minimum for winching
Battery Leads 2 gauge. 72"(1.83mm)
Finish Grey Metallic
Weight N.W. 88lbs(40kg) G.W. 95lbs(43kg)
Overall dimensions (LxWxH) 21.3" x 6.3* x 8.6" (562 x 160 x
218mm)
Mounting Bolt Pattern 10.00*0.015" x 4.50±0.010" (254 x 114.3mm)
Layer of cable 1 2 3 4
Rated line pull per layer Lbs 12000 9210 8030 6894
Kgs 5440 4170 3640 3125
Cumulative cable
capacity Lbs 17 41 71 82
Kgs 4.8 12 21 25
Line Pull Lbs 12000
kgs 5440
Line Speed ft/mm 5.5
m/min 1.7
Motor Current amps 360

TWO (2) YEAR WARRANTY FOR MECHANICAL COMPONENTS
LIMITED ONE (1) YEAR WARRANTY FOR ELECTRICAL COMPONENTS
ROUGH COUNTRY warrants to the original purchaser that (a) the mechanical components of the Rough Country
winch will be free of defects in material and workmanship for a period of two (2) years, and (b) the electrical
components will be free of defects in material and workmanship for a period of one (1) year from the original
purchase date. The warranty applies to the original purchaser of the winch. To obtain any warranty service, you
must provide Rough Country with proof of purchase and date of purchase to Rough Country; such as a copy of
the original purchase receipt. This warranty does not cover the removal or reinstallation of the winch. Rough
Country will; at its option, repair , replace or refund the purchase price of a defective winch or component, pro-
vided you return the defective winch or component during the warranty period, transportation charges prepaid,
to Rough Country’s service department or factory authorized service center. Upon approval to return the winch
from Rough Country and after receiving a RGA from Rough Country, attach your name, address, telephone
number, a description of the problem and a copy of your receipt and original bill of sale bearing the Rough
Country serial number of the defective winch and date of purchase.
This warranty does not apply (1) to finish and wire rope, or (2) if the winch has been damaged by accident,
abuse, misuse, collision, overloading, modification, misapplication, improper installation, or improper service.
This warranty is void if a Rough Country serial number has been removed or defaced. Commercial or industrial
use or application, or any hoisting application of the winch voids the warranty.
THE WARRANTY SET FORTH ABOVE IS THE ONLY WARRANTY. THERE ARE NO OTHER WARRANTIES, EX-
PRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FIT-
MESS FOR A PARTICULAR PURPOSE.
TO ONE (1) YEAR FROM THE DATE OF ORIGINAL RETAIL PURCHASE OF THE PRODUCT.
No Rough Country dealer, agent or employee is authorized to make any modifications, extension or addition to
this warranty.
ROUGH COUNTRY SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAM-
AGES (INCLUDING BUT NOT LIMITED TO, LOST PROFITS, DOWN TIME OR LOSS OF USE). UNDER ANY LEGAL
THEORY, EVEN IF ROUGH COUNTRY WAS ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
By purchasing any item sold by Rough Country, LLC, the buyer expressly warrants that he/she is in compliance
with all applicable Federal, State, and Local laws and regulations regarding the purchase, ownership, and use
of the item. It shall be the buyers responsibility to comply with all Federal, State and Local laws governing the
sales of any items listed, illustrated or sold. The buyer expressly agrees to indemnify and hold harmless Rough
Country, LLC for all claims resulting directly or indirectly from the purchase, ownership, or use of the items.
Some dates do not allow the exclusion of implied warranties or the exclusion or limitation of liability for inciden-
tal or consequential damages or limitations on how long an implied warranty lasts. So the above limitation or
exclusion may not apply to you. This warranty gives you specific legal rights, you may also have other rights
that vary from state to state.
Rough Country reserves the right to change product design without notice. In situations in which Rough Coun-
try has changed a product design, Rough Country shall have no obligation to upgrade or otherwise modify pre-
viously manufactured products.
Warranty inquiries and products returned for warranty service should be sent to:
ROUGH COUNTRY RECOVERY SYSTEMS
750 HWY 77 EAST
NEWBERN, TENNESSEE 38059
LOCAL:731-285-9000 TOLL FREE:800-222-7023
Products Covered By This Warranty
Recreational vehicle winches Products Not Covered By This Warranty Finish and wire rope for recreational vehicle winches

TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE SUGGESTED REMEDY
Motor does not turn on
-Switch Assembly not connected properly *Insert Switch Assembly firmly to the con-
nector
-Loose Battery Cable *Tighten nuts on cable connectors
-Solenoid Malfunctioning *Tap solenoid to free contact, applying 12
volts to coil terminal directly.
-Defective Switch assembly *Replace Switch Assembly
-Water has entered the motor *Drain and dry. Run in shirt bursts with-
out load until completely dry
Motor runs too hot -Long period of operation *Let winch cool down periodically
Motor runs too slowly or
without normal power
-Battery depleted *Recharge battery by running vehicle en-
gine
-Insufficient current or voltage *Clean, tighten or replace the connector
Motor runs but cable drum
does not turn -Clutch (Cam Ring) not engaged *Push Cam Ring into IN position. If that
does not work, a qualified technician will
need to check and repair
-Defective or stuck solenoid *Tap solenoid to free contacts. Repair or
replace solenoid
-Defective Switch Assembly *Replace Switch Assembly
Motor runs in one direction
only