Smittybilt XRC 3.0 User manual

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Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
Parts Included Qty Parts Included Qty
Winch with Wire Rope 1 Remote Control 1
Winch Plate 1 Handle Bar Control 1
Clevis Hook 1 Hardware Pack 1
NOTE: Read, study and follow all instructions before operating and installing this product. Failure
to heed these instructions may result in personal injury and/or property damage.
This winch can develop tremendous pulling forces and if used unsafely or improperly
could result in property damage, serious injury or death. Throughout this manual you
will notice headings such as Caution, Warning and Danger. Pay particular attention
to these headings as they are written for your safety.. Ultimately, safe operation of this
product rests with you, the operator.
WINCH ASSEMBLY AND MOUNTING
1. Your winch is designed with a bolt pattern that is standard in this class of winches. Many
winch mounting kits are available that utilize this bolt pattern for the most popular ATV’s and
mounting channels.
2. Regardless of the mounting kit you use, ensure that your winch is mounted on a flat surface
so that the three major sections (motor, drum and gear housing) are properly aligned. Proper
alignment of the winch will allow even distribution of the full rated load.
3. Utilize the M8x30 mounting bolts, washers and nuts included.
4. Connect the battery (4’ 1”) and motor (5’ 9”) leads. Connect the red positive (+) to the in-facing
terminal marked (+) on the motor and the black negative (-) to the out-facing terminal marked (-) on
the motor. Then connect the red positive (+) lead from the power switch to the positive (+) terminal
of the vehicles 12 volt battery. Connect the black negative (-) lead from the power switch to the
negative (-) terminal of the battery. (Caution: Batteries contain gases which are flammable and
explosive. Wear eye protection during installation and remove all jewelry. Do not lean over battery
when making connections.

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Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
5. Assemble the clevis hook to the cable. Pull and turn the clutch knob to the “Off” position (Free
spooling),pull out some cable from the drum. Take the pin from the clevis hook, connect the clevis
hook to the cable and mount the pin back to the clevis hook.
6. Always use the hand saver when free-spooling and re-spooling the wire rope. Using the hand
saver keeps your hands and fingers away from the rotating drum.
7. Check for proper drum rotation. Pull and turn the clutch knob to the “off” position (free-spooling).
Pull out some cable from the drum, then turn the clutch knob to the “in” position to engage the
gears. Press the cable out button on the power switch. If the drum is turning and releasing more
cable then your connections are accurate. If the drum is turning and collecting more cable then
reverse the leads on the motor. Repeat and check rotation.
Hand Remote

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Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
Handle Bar Switch Assembly
When installing your ATV 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 exist before energizing your winch circuit.
To install the complete kit, you will need to mount the winch, contactor handlebar mounted mini-
rocker switch and remote socket. Mounting locations may vary depending on the make and model
of the ATV. Read and understand the following instructions to choose the appropriate mounting
locations.
It is recommended that the switch be installed on left handlebar. A piece of electrical tape around
the handlebar will help prevent rotation of mount on the handle bar. Do not tighten over and hoses
or cables. Once the handle bar switch is mounted, route the two bullet terminal wires back to where
the contactor will be mounted. Splice the end of the red 20ga wire to key controlled electrical wire of
the ATV. Using a test light, locate a suitable wire from the ATV key switch. The wire should only
have power when the key is in the “ON” position.

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Smittybilt, 400 West Artesia Blvd, Compton, CA 90220
Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
Handlebar mount-Exact location may
vary depending on ATV make and
model.
Mini-rocker switch
assembly
Use a test light to locate
a suitable wire

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Smittybilt, 400 West Artesia Blvd, Compton, CA 90220
Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
SAFTEY PRECAUTIONS
!WARNING!
Do not Exceed Rated Capacity.
Intermittent use only.
Do not use winch in lifting or moving persons.
A minimum of five wraps of cable around the drum barrel is necessary for pulling and holding the
rated load. The cable clamp is not designed to hold the load without 5 wraps of cable around the
barrel.
Keep yourself and others a safe distance to the side of the cable when under tension.
The wire rope may break before the motor stalls. For heavy loads at our near rated capacity, use a
pulley/snatch block to reduce the load on the wire rope.
Never step over a cable or near a cable under load.
Don’t move the vehicle to pull a load (towing) on the winch cable. This could result in cable
breakage.
Disconnect the remote control and battery leads when not in use.
Do not exceed maximum pull rating. Avoid “shock loads” by using the control switch intermittently to
take up the slack in the wire rope. “Shock loads” can far exceed the rate capacity for the wire rope
and drum.
Do not exceed maximum line pull ratings shown in the tables.
Do not use as a hoist. Do not use for overhead lifting.

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Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
When re-spooling the cable, ensure that the cable spools in the under-wind position with the cable
entering the drum from the bottom and not the top. To re-spool correctly, and while wearing gloves,
keep a slight load on the cable while pushing the remote button to draw in the cable. Walk toward
the winch not allowing the cable to slide through your hands. Do not let your hands get within 12” of
the winch while re-spooling. Turn off the winch and repeat the procedure until a few feet of cable is
left. Disconnect the remote control and finish spooling by hand by rotating the drum by hand with
the clutch disengaged. Keep hands clear of the fairlead and drum while the winch is under power.
Failure to heed these warnings may result in personal injury or property damage.
CAUTION
Use gloves to protect hands when handling the cable. Never let the cable slide through your hands.
Apply blocks to the wheels of the vehicle when on an incline.
No modifications, alterations, or deviation to the winch are authorized by the manufacturer and
should not be made.
Duration of winching pulls should be kept as short as possible. If the motor becomes uncomfortably
hot to the touch, stop winching immediately and let it cool down for a few minutes.
Do not pull for more than one minute at or near the rated load.
If the motor stalls do not maintain power to the winch. Electric winches are designed and made for
intermittent use and should not be used in constant duty applications.
Never release the free-spool clutch when there is a load on the winch.
Use hand saver hook when handling the hook for spooling or un-spooling the wire rope.

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Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
GENERAL TIPS FOR SAFE OPERATION
The XRC3.0 is rated at 3,000lbs capacity when spooling the first layer on the drum. Overloads can
damage the winch/motor/or wire rope. For loads over 50% we recommend the use of a
pulley/snatch block to double the wire rope line. This will help in two ways, 1) reduce the number of
rope layers on the drum, 2) reduce the load on the wire rope by as much as 50%. When doubling
the line back to the vehicle, attach to the frame or other load bearing point.
The vehicle engine should be kept running during operation of the winch to minimize battery drain
and maximize power and speed of the winch. If the winch is used for a considerable time with the
engine off the battery may be drained and too weak to restart the engine.
Get to know your winch before you actually need to use it. We recommend that you set up a few
test runs to familiarize yourself with rigging techniques, the sounds your winch makes under various
loads, the way the cable spools on the drum, ect….
Inspect the wire rope and equipment before each use. A frayed or damaged cable should be
replaced immediately. Use only manufacturer’s identical replacement cable with the same
specifications.
Inspect the winch installation and bolts to ensure that all bolts are tight before operation.
Never connect the cable back to itself. This will cause cable damage. Always use a snatch block,
sling or chain of suitable strength as shown the illustrations.
Store the remote control inside your vehicle in a place that it wont get damaged.
Any winch that appears to be damaged in any way, is found to be worn, or operates abnormally
need to be removed from service until repaired. It is recommended that the necessary repairs be
made by an authorized winch repair facility.
Pull only on areas of the vehicle as specified by the vehicle manufacturer.
Only attachments and/or adapters supplied by the manufacturer should be used.

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Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
RIGGING TECHNIQUES
WINCHING TECHNIQUES A-Z
A. Take your time to asses your situation.
B. Put gloves on to protect your hands.
C. Disengage the clutch to allow free-spooling and also save battery power.
Locate a suitable anchor such as a strong tree trunk or boulder.
Always use a sling as an anchor point. Caution: Do not attach clevis hook back
onto cable as this could cause damage to the cable.
Self Recovery
Do not winch from an acute angle as the wire rope will pole up on one side of the
drum causing damage to the wire rope and winch.
Short pulls from an angle can be used to straighten the vehicle.
When pulling a heavy load, place a blanket or jacket over the wire rope five
or six feet from the hook. In the event of a broken cable it will dampen the
snap back.
For pulls over 1,000lbs we recommend the use of a snatch block/pulley
block to double the line.
This reduces the load on the winch and strain on the wire by approx 50%
WARNING:
Never use your winch for overhead hoisting or for lifting
people or moving people.
wrong
correct

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Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
D. Attach the hand saver hook strap to the clevis hook.
E. Pull out the wire rope to your desired anchor point using the hand saver strap.
F. Secure the clevis hook to the anchor point sling, chain or snatch block. Do not attach the
hook back onto the wire rope.
G. Engage the clutch.
H. Connect the remote control to the winch.
I. Start your engine to ensure power is being replenished to the battery.
J. Power in the wire rope guiding the wire under tension to draw up the slack in the wire. Once
the wire is under tension stand well clear. Never step over the cable.
K. Double check your anchors and make sure all connections are secure.
L. Inspect the wire rope. Make sure there are at least 5 wraps of wire rope around the winch
drum.
M. Drape a blanket or jacket over the wire rope approximately 5 to 6 feet from the hook. Open
the hood for added protection id applicable.
N. Clear the area. Make sure all spectators are well back and that no one is directly in front or
behind the vehicle or anchor point.
O. Begin winching. Be sure that the wire rope is winding evenly and tightly around the drum.
The vehicle that is being winched can be slowly driven to add assistance to the winding
process. Avoid shock loads; keep the wire rope under tension.
P. The vehicle to be winched should be place in neutral and the emergency brake released.
Only release the brake pedal when under full tension. Avoid shock loads to the winch. This
can damage the winch, rope and vehicle.
Q. The winch is meant for intermittent use. Under full load with a single ling rig do not power in
for more that a minute without letting the motor cool down for a few minutes and the resume
winching operation.
R. The winching operation is complete once the vehicle is on stable ground and is able to drive
under its own power.
S. Secure the vehicle. Be sure to set the brake and place the vehicle park.
T. Release the tension on the wire rope. The winch is not meant to hold the vehicle for long
periods of time.
U. Disconnect the wire rope from the anchor.
V. Rewind the wire rope. Make sure that any wire already on the drum has spooled tightly and
neatly. If not, draw out the wire and re-spool from the point where the rope is tight.
W. Keep your hands clear of the winch drum and fairlead as the wire rope is being drawn in.
X. Secure the hook and hook strap.
Y. Disconnect the remote control and store in clean, dry and secure place.
Z. Clean and inspect the connection and mounting hardware for next needed operation.

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For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 West Artesia Blvd, Compton, CA 90220
Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
MAINTENANCE
1. Periodically check the tightness of the mounting bolts and electrical connections. Remove all dirt
or corrosion and always keep clean.
2. Do not attempt to disassemble the gear box. Repairs should be done by and authorized repair
center.
3. The gear box has been lubricated using a high temperature lithium grease and is sealed at the
factory. No internal lubrication is required.
REPLACING THE WIRE CABLE
1. If the wire cable has become worn or is beginning to show signs of strands breaking it must be
replaced before being used again. To do this, remove the defective cable be free spooling it out.
Remove the 5 x 5mm bolt on the drum and release the cable.
2. Insert the end of the new cable and secure with the previously removed bolt.
3. Engage the clutch and re-spool the new cable on the drum keeping tension on the cable as it
spools. Ensure that the cable is re-spooling in the under wind position.
NOTE: Only replace the cable with the identical manufacturer’s cable.

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Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
TROUBLE SHOOTING

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Smittybilt, 400 West Artesia Blvd, Compton, CA 90220
Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
NO S.B part# QTY Description
1 97203-01 1 Motor
2 97203-02 1 gasket
3 97203-03 1 bearing
4 97203-04 1 bearing bushing
5 97203-05 1 brake base
6 97203-06 1 brake gear
7 97203-07 1 drum support motor side
8 97203-08 2 drum bushing
9 97203-09 2 tie rod
10 97203-10 1 bushing for water proof
11 97203-11 2 o-ring for water proof
12 97203-12 1 drum
13 97203-13 1 spring
14 97203-14 2 Split snap ring
15 97203-15 1 shaft
16 97203-16 1 gear box cover
17 97203-17 1 Gasket
18 97203-18 1 splined gear
19 97203-19 1 Gear carrier assembly state 3
20 97203-20 1 Gear carrier assembly state 2
21 97203-21 1 Gear carrier assembly state 1
22 97203-22 1 sun gear
23 97203-23 1 gasket
24 97203-24 1 Slide block for clutch
25 97203-25 1 gear ring
26 97203-26 1 gear box body
27 97203-27 1 bushing
28 97203-28 1 clutch knob
29 97203-29 1 wire rope and hook
97203-30 1 Remote
97203-31 1 Handle Bar Control
97203-32 1 Winch Plate
97203-33 1 Solenoid

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For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 West Artesia Blvd, Compton, CA 90220
Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203

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For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 West Artesia Blvd, Compton, CA 90220
Installation Instructions
XRC 3.0 3,000lb Winch
Part # 97203
XRC 3.0 (3,000lb) WINCH
Line Pull lbs 0 1000 2000 3000
kg 0 454 907 1361
Line Speed ft/min 24.5 14.7 10.5 6.9
m/min 7.5 4.5 3.2 2.1
Motor Amps 15 75 120 175