Strongarm TW4000 User manual

5% 10% 20% 30% 50% 70%
(3°) (6°) (11°) (17°) (26°) (35°)
TW4000 10,000 lbs. 7,500 lbs. 5,100 lbs. 3,900 lbs. 2,700 lbs. 2,200 lbs. 1500 lbs.
4,536 kg 3,402 kg 2,313 kg 1,769 kg 1,225 kg 998 kg 681 kg
TW9000 20,000 lbs.15,000 lbs.10,200 lbs. 7,700 lbs. 5,500 lbs. 4,500 lbs. 3,000 lbs.
9,072 kg 6,804 kg 4,627 kg 3,493 kg 2,495 kg 2,041 kg 1,362 kg
12 Volt DC
ELECTRIC
TRAILER
WINCHES
WARNING: READ INSTR CTIONS CAREF LLY
BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE
THE STRONGARM ELECTRIC WINCH. FAIL RE TO COMPLY
WITH INSTR CTIONS CO LD RES LT IN SERIO S OR FATAL
INJ RY. RETAIN INSTR CTIONS FOR F T RE REFERENCE.
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StrongArm TW electric trailer winches are manufac-
tured for loading and unloading of boats, personal
watercraft, vehicles, etc. The TW4000 winch fea-
tures power-in, free wheel out and 20' of 2" wide
strap. The TW9000 features power-in, power-out,
free wheel and 20' of 2" wide strap.
Note that as strap builds up on the reel, the pulling
capacity of the winch decreases (see graph at left).
or intermittent use only. Ratings at left are based
on 6' pull. or longer pulls adequate motor cooling
periods must be allowed.
TW4000-MAXIMUM CONTINUOUS RUN TIME
3 MINUTES
TW9000-MAXIMUM CONTINUOUS RUN TIME
4 MINUTES
CAUTION: CONTINUOUS RUNNING IN
EXCESS OF 3 INUTES (TW4000) AND 4 IN-
UTES (TW9000) WILL DA AGE WINCH OTOR.
GUIDE TO ROLLING LOAD CAPACITY**
aximum weight in pounds and kilograms rolling load.
APPROXI ATE LOAD SPEED
(FT./ IN.)
ODEL PERCENT INCLINE
LOAD
CAPACITY
(**) All capacities shown are with 2' of strap on the reel and 10% rolling friction factor.
or full reel of line adjust capacities according to graph above. Note 5% incline is
one-half foot rise in ten feet.
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WINCH RATINGS
TW series electric winches are built for trailer loading and other horizontal pulling applications. They are not to
be used for lifting, supporting or transporting people or loads over areas where people could be present or for
any vertical lifting or lowering applications.
NO LOAD ULL LOAD
ull Empty ull Empty
Reel Reel Reel Reel
TW4000 22 11 8.2 4.4
TW9000 15 9 6.3 4.3
500
1000
1500
2000
2500
3000
3500
0
10 20 30 40
TW 9000
TW 4000
DEAD WEIGHT CAPACITY (LBS.)
LENGTH O STRAP ON REEL ( T.)
ELECTRIC WINCH RATING
E
N
G
L
I
S
H
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TW4000 & TW9000 OWNER’S MANUAL
TW4000

This electric winch should be respected as power
equipment. High forces are created when using a
winch, creating potential safety hazards. Never
allow children or anyone who is not familiar with
the operation of the winch to use it.
Never exceed rated winch load. Dangerously high
forces can be created if the load being moved is
too large or is allowed to get in a bind, etc. Pay
attention to the sound of the winch and stop
pulling immediately if the winch begins to stall.
Note that installing longer than normal line results
in increased load on the winch.
Winch is equipped with high-quality strap capable
of handling the rated winch load. Never exceed
the rated capacity. Do not use vehicle pulling
power to increase the pulling capacity of your
winch.
Keep the winching area free of all unnecessary
personnel. Never stand between load and winch
or directly in line with load and winch.
This winch operates from a low voltage 12 volt
D.C. power source (e.g., a car or truck battery).
DO NOT connect winch to 120V A.C. power.
When winching operation has been completed,
do not depend on the winch to support the load.
Always secure the load properly. Use tie down
straps or chains.
The auxiliary handle is for emergency use only.
Never use the auxiliary handle as an assist to the
motor when the motor is running. Always remove
the auxiliary handle when it is not in use. Do not
operate the winch motor or allow the winch to free
wheel with the handle installed.
Keep hands and fingers clear of the drum and
line area of the winch when operating. Do not
attempt to guide the line by hand as it rewinds on
the drum.
The winch must be securely attached to a struc-
tural member or frame that is capable of sustain-
ing loads in excess of the winch capacity. When
attaching the winch to a vehicle, make sure the
mounting pad area is rigidly supported by the
vehicle frame. Always block the wheels to prevent
vehicle from rolling when pulling a load with the
winch.
When releasing a load with the clutch, maintain
control of the speed. Excess speed could result in
winch damage and serious personal injury.
Keep the pull of the strap onto the reel as straight
as possible to avoid strap damage.
Inspect strap and hook on each use and replace
at the first sign of wear or abnormal appearance.
I PORTANT SAFETY INFOR ATION
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OUNTING INSTRUCTIONS
1. Be sure that the mounting surface is of sufficient
strength to support a load well in excess of the rated
winch capacity.
2. asten the winch to the trailer winch stand (or other
mounting surface) with three 1/2" bolts, nuts, washers
and lock washers. Be sure that the winch is positioned
so that the strap winds onto the reel as straight as
possible.
3. On boat trailer installations the winch stand should be
adjusted so that the loading ring on the bow of the
boat is at the same height or slightly higher than the
winch drum when the boat is fully loaded on the trailer.
Be sure that the trailer-bow stop is located far enough
back of the winch drum so that the strap hook is not
drawn into the drum when the boat is fully loaded on
the trailer.
4. Your winch is equipped with keyhole slots in the base
for use with quick mounting shoulder studs, if desir-
able. (See IG. 1) If you wish to use quick mount
studs, (DL Accessory No. 6365) they should be
mounted securely into the winch stand. After position-
ing the winch on the studs, a 3/8" bolt should be
placed in one of the other holes available to keep the
winch securely in position.
WARNING: FAILURE TO READ AND FOLLOW INSTRUCTIONS BELOW COULD RESULT IN
SERIOUS OR FATAL INJURY.
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WARNING: This winch is built for trailer loading and other horizontal pulling applications. NOT TO BE
USED FOR LIFTING, SUPPORTING OR TRANSPORTING PEOPLE OR LOADS OVER AREAS
WHERE PEOPLE COULD BE PRESENT OR FOR ANY VERTICAL LIFTING OR LOWERING
APPLICATIONS.

The wiring harness is designed to remain in the trunk of
the car when not in use. This prevents tampering, accident
or misuse since the harness is needed to operate the
winch electrically.
These installation instructions provide ready access for
use, yet allow the complete harness to be quickly removed
if desired.
1. eed positive lead (long) wire only through any con-
venient access hole inside the car trunk. It may be nec-
essary to remove a knockout plug or rubber grommet
from the trunk floor. It may also be necessary to
remove the circuit breaker assembly from the positive
wire in order to feed the wire under the car.
2. Pull the positive lead wire along the underside of the
car into the engine compartment and up to the battery.
asten the wire to the car undercarriage with existing
wiring clamps and brackets, making sure wire is not
located near the exhaust system, or any hot or moving
parts. Wire should be fastened securely and without
slack. Excess wire should remain in the trunk.
3. asten the circuit breaker to the positive (+) battery
terminal (if nut and bolt type) or to the battery side of
the starter solenoid.
4. Attach negative wire to vehicle frame using a 1/4" bolt
and locknut. Make sure you have a clean, tight con-
nection.
NOTE: If winch is to be mounted in front of vehicle, cut
harness to the length needed making sure, if spliced,
the splice is tight and well insulated. Attach ground as
described in 4 above.
ODEL TW4000
1. Attach the plug end of the power supply (wiring har-
ness) into the connector located at the back of the
winch. This pushes and snaps into place easily and
will only fit in one direction. With the clutch knob in the
“Engaged” position, activation of the toggle switch on
the side of the winch will power a load in. The switch is
spring loaded and will stop the winch and lock the
load in position when toggle is released. Leave your
car engine running on fast idle as a precaution in case
the battery is not in top condition.
2. Always disconnect the power when winching opera-
tion is complete. To disconnect power supply, simply
pinch the top and bottom locking device on the plug
end with fingers and pull out.
3. or remote switching, place looped spring on toggle
switch and attach lanyard.
ODEL TW9000
1. Attach the plug end of the power supply (wiring har-
ness) into the connector located at the back of the
winch. This pushes and snaps into place easily and
will only fit in one direction. With the clutch lever in the
“Engaged” position, you may power the winch in either
the load or unload direction. The switch is spring
loaded and will stop the winch and lock the load in
position when switch lever is released. Leave your car
engine running on fast idle as a precaution in case the
battery is not in top condition.
2. Always disconnect the power when the winching
operation is complete. To disconnect power supply
simply pull the plug end of power supply from the
winch.
NOTE: It is normal for smoke to be produced during
the initial power down use.
3. or remote switching, attach lanyard to hole in switch
lever.
TW4000 AND TW9000
WARNING: EVEN THOUGH THE WINCH IS
EQUIPPED WITH CIRCUIT BREAKER OVERLOAD
PROTECTION, PARTICULAR CARE SHOULD BE
TAKEN NOT TO CREATE AN OVERLOAD. PAY
ATTENTION TO THE SOUND OF THE WINCH AND
THE LOAD BEING PULLED. AKE CERTAIN THAT
THE STRAP TENSION DOES NOT RISE SUDDENLY
BECAUSE OF A BIND IN THE LOAD.
CAUTION: The electric motor is designed for inter-
mittent service only. Extended use without cooling
off periods will cause overheating resulting in
motor damage. aximum recommended continu-
ous run time is three minutes (TW4000) and four
minutes (TW9000).
CAUTION: These winches are built for trailering
boats, PWCʼs, vehicles, etc. Secure the load onto
the trailer with appropriate bow and transom tie
down straps or chains. With the load fully secured
on the trailer, it is advisable to relieve the tension
on the winch strap to avoid damage to the winch
and trailer due to high shock loads encountered
when traveling.
1. The knob (TW4000) or clutch lever (TW9000) pro-
vides a means for releasing a load without power
while maintaining control of the speed and provides
for freewheeling so that strap can be removed from
the winch by hand. The clutch lever on the TW9000 is
spring loaded so that it returns to the engaged posi-
tion when released. The lever will, however, remain in
the freewheeling position if rotated completely forward
to freewheel.
LOADING AND UNLOADING
UNDER POWER
WIRING HARNESS INSTALLATION
IG. 1
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CLUTCH OPERATION

2. In order to release a load without power, rotate the
knob or clutch lever slowly and carefully forward
toward “ reewheel.” When the load begins to move, it
can be controlled by the knob or clutch lever. Careful,
slow movement of the knob or lever will provide
smooth control of the load.
WARNING: ALWAYS AINTAIN CONTROL OF THE
LOAD. ALLOWING EXCESS SPEED COULD
RESULT IN WINCH DA AGE AND SEVERE PER-
SONAL INJURY.
3. Remember that the gear train and brake mechanism
are completely disengaged in the “ ree Wheel” posi-
tion and in order to power the winch or hold a load in
position, the knob or lever must be returned to the
“Engaged” position.
NOTE: On the TW9000 it is not necessary to turn the
clutch lever completely to the “Engaged” position man-
ually. The spring tension built into the winch provides
adequate force on the clutch lever.
CAUTION: Never force knob or clutch lever in
either direction.
An emergency crank handle is provided for the model
TW9000 for use in the event of a power failure. The model
TW4000 requires the use of a ratchet wrench and 5/8"
deep well socket or a standard 5/8" socket with an exten-
sion.
1. Disconnect the electrical power from the winch and
remove the plastic plug from the side of the winch
housing.
WARNING: NEVER OPERATE THE WINCH ELEC-
TRICALLY WITH THE E ERGENCY HANDLE OR
RATCHET WRENCH IN POSITION.
TW4000
2. Insert the 5/8" socket and
ratchet handle so that it com-
pletely engages with the
drive shaft. Turn the drive
shaft in the counterclock-
wise direction only. (See
ig. 2)
WARNING: KEEP THE
CLUTCH KNOB IN THE
“ENGAGED” POSITION
WHILE CRANKING WINCH.
DO NOT PUT CLUTCH IN
“FREE WHEEL.”
TW9000
2. Insert the emergency handle so it completely engages
with the drive shaft. Pull in strap by turning the handle
in the clockwise direction (See ig. 2A). To make
cranking easier, the clutch handle can be placed in the
“free wheel” position while holding onto the emer-
gency crank handle.
WARNING: IF THE CLUTCH IS PLACED IN FREE
WHEEL FOR HAND CRANKING, BE SURE TO
AINTAIN A FIR GRIP ON THE HANDLE AT ALL
TI ES.
Because the TW9000 emergency crank handle
attaches to the clutch side of
the winch, it is equipped with
a spring-operated clip which
will be depressed by the
clutch handle in the free
wheel position when crank-
ing in a clockwise direction to
retrieve strap. This clip is a
safety feature and will re-
enage the clutch mechanism
in the event the operator
loses control of the handle
with a load on the winch.
WARNING: EVEN WITH
THIS SAFETY FEATURE, THE HANDLE WILL SPIN
VIOLENTLY ONE OR TWO TURNS BEFORE RE-
ENGAGING THE CLUTCH TO STOP THE WINCH.
DO NOT LOSE CONTROL.
3. Always remove the handle from the winch after use
and replace the plastic plug.
or long life and trouble-free operation your winch
should periodically be inspected for any required mainte-
nance. This should be done at least once annually and
more frequently in adverse conditions such as salt water
areas or areas of extreme dust and dirt.
WARNING: BEFORE PERFOR ING ANY AINTE-
NANCE BE SURE THERE IS NO LOAD ON THE
WINCH AND THAT THE POWER HAS BEEN
DISCONNECTED.
1. Carefully inspect the winch strap and replace at the
first sign of damage. In order to replace the winch
strap, it is necessary to remove the winch cover. On
the TW4000, remove the slotted nut in the end of the
knob with a screwdriver and unscrew the knob from
clutch stud. Remove the nut holding the toggle switch
into the cover and push the switch inside the winch.
Remove the six cover screws and lift the cover from
the winch while gently stretching it open to clear the
clutch stud. On the TW9000, remove the clutch handle
by removing the two clutch handle screws and then
remove the six cover screws. Lift the cover from the
winch while gently stretching it open to clear the clutch
stud.
Rotate the winch reel to gain access to the strap bolt.
Remove the old strap and replace it with a new strap
of the same size. If the strap bolt is bent, replace it
with a bolt of the same size and length. Note that nut
on the strap bolt must be on gear side of winch reel
and locknut must be used. Do not substitute free run-
ning nut. Slide bolt to bottom of slot and tighten nut
until snug. Do not over tighten, strap will hold bolt in
bottom of slot.
NOTE: STRAP IS WOUND OVER THE TOP O THE
DRUM ON MODEL TW4000 AND UNDER THE
DRUM ON MODEL TW9000.
2. With the cover removed as described above, inspect
the entire gear train and all drive shafts for any signifi-
cant wear or loose bearing fits. Also, check all nuts,
bolts, retaining rings, etc., to be sure that they are tight
and secure. Grease all of the gears on the inside of
the winch base and apply a drop of oil on all of the
bearings in the base. Also, very sparingly oil all of the
WINCH AINTENANCE
AUXILIARY HANDLE
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Socket & Ratchet
Handle Illustration
(TW4000)
IG. 2
Emergency Handle
Illustration (TW9000)
IG. 2A

SY PTO POSSIBLE CAUSE(S) CORRECTIVE ACTION
Safety hook spreads 1. Point loading of hook. 1. Replace hook.
2. Load exceeds rated capacity of unit. 2. Lighten load, reduce % of incline or reduce load friction.
Strap breaks 1. Improperly maintained strap. 1. See “Maintenance.”
2. Overloading. 2. Reduce load.
Strap folds over (binds up) Pulling load at too severe of Make straighter pulls.
an angle.
Load creeps when power is O 1. Clutch out of adjustment. 1. TW4000 - tighten knob. TW9000 - adjust (see
Maintenance)
2. Roller clutch, not engaging. 2. Replace.
3. Overloading. 3. Reduce load.
Winch does not hold load Strap wound on drum incorrectly. Strap must be wound over top of drum on TW4000 & under
the drum on model TW9000.
Winch motor runs hot In operation too long. Let motor cool for at least 20 minutes. (See Winch Rating
Section.)
Winch motor fails to run Electrical. Check the following: power supply, wiring, control
switch, male/female connections, motor and circuit
breakers.
Winch motor runs but fails 1. Clutch is slipping. 1. Check clutch lining for grease or oil. See “Maintenance”
to wind strap for clutch adjustment procedure.
2. Gear train is damaged. 2. Check entire gear train and replace any damaged parts.
Strap will not pull out (freewheel) Sticking clutch. a. “Jog” power switch with clutch in freewheel (No load only).
b. Remove cover (see Maintenance) and separate clutch
gear from mating gear.
Smokes (TW9000 only) Normal on initial power down use. None.
TROUBLESHOOTING CHART
bearings in the clutch mechanism and place a drop of
oil on the roller clutch. Do not over lubricate these
areas and do not use grease in the roller clutch. The
clutch mechanism and the brake pads and brake disc
on the TW9000 must be kept clean and oil free.
ADDITIONAL AINTENANCE TW9000
3. Check the operation of the roller clutch in the brake
disc assembly (A ). Carefully rotate the brake disc
and observe the motor shaft. When the disc is turned
clockwise the motor shaft should turn with it. When the
disc is turned counterclockwise the motor shaft should
not turn.
4. If the clutch has been slipping and requires adjust-
ment the following procedures should be used. The
clutch is adjustable in ten degree increments. With a
screwdriver and pliers, remove the end of the clutch
spring from the hole in the winch base. The spring
tension is quite high so be careful to maintain a firm
grip on the spring. The O-ring should be rotated so
that the cut out portions align with the lugs on the
spring keeper. (See IG. 3)
The ring can then be expanded with a pencil or similar
object and the spring keeper can be lifted free from
the clutch nut. Rotate the keeper clockwise 10
degrees and install on the next serration in the clutch
nut. Reinstall O-ring and rotate slightly so that the cut
outs are not in line with the lugs on the spring keeper
and reinstall the clutch spring into the hole in the
base. Adjustment of the clutch more than 10 degrees
to 20 degrees should normally not be necessary. With
only spring pressure (do not forcibly tighten the clutch
mechanism) the spring lug on the spring keeper
should come to rest at approximately the 2:30 o’clock
position. (See IG. 4)
IG. 3 IG. 4
O-Ring Illustration (TW9000) Clutch Spring Illustration (TW9000)
Spring Lug
Horizontal
Adjust to this posi-
tion (2:30 oʼclock)
Clutch Spring
Keeper
Clutch Spring

TW4000 PARTS LIST
Ref. Part Number
A Retaining Ring 204468
B Bushing 204006
C Drive Shaft Ass’y 304967
D 56T Gear 204703
E Retaining Ring 205191
F Base Shroud - Left 404834
G Base Shroud - Right 404833
H Screw (6) 205337
Base 404940
K Hex Nut 406002
L Locknut 10-32 (3) 205193
M Stop 404829
N Washer 205109
P Washer 203813
Q ‘E’-Ring 205135
R Motor Pinion 206228
S Roller Clutch Ass’y 304698
T Reel Shaft 404559
U Base Spacer 404557
V Spacer (4) 404822
X Reel Ass’y 304858
Z Motor 304695
Ref. Part Number
AA Cover Plug 204713
BB Cover Ass’y 304684
CC Mounting Screw (6) 205086
EE Screw (4) 205338
FF Strap 2" x 20' 5242607
GG Locknut 7/16-20 205192
HH Washer (2) 204360
Thrust Bearing Replacement Kit 5703194
KK 120 Tooth Gear Ass’y 304409
LL Clutch Stud 404826
MM Clutch Gear Ass’y 304305
NN Finger Spring Washer 205200
PP Bushing 204012
QQ Front Plate 404825
RR Knob 206243
SS Slotted Nut 404614
TT Wiring Harness 5240411
UU Connector 206240
VV Toggle Switch 206249
WW Toggle Switch Guard 404831
WIRING DIAGRAM
To order replacement parts contact:
Dutton-Lainson Company
www:dlco.com
Tel: [phone]
ax: 402-460-4612
e-mail: [email protected]
In Europe Contact:
Aqua- arine International Ltd.
8 landers Park
Hedge End, Southampton
Hants, England SO30 2 Z
Tel: [phone]
ax: [phone]
e-mail: [email protected]

TW9000 PARTS LIST
Ref. Part Number
A Bearing Housing Assy. 304314
B Primary Drive Shaft Assy. 304304
C Retaining Ring (2) 205191
D Bushing (2) 204012
E 56T Gear 204703
F Aux. Handle Assy. 5703079
G Drive Shaft Bushing 304313
Housing Assy.
Interm. Drive Shaft Assy. 304814
K “E” Ring 205116
L Base 404932
M Nut, 7/16-20 Locknut 205192
N Clutch Stud 404517
P Clutch Handle Replacement Kit 5703178
(Includes Items V, W, AX & AY)
Q Thrust Bearing Replacement Kit 5703194
(Includes Item W, O-Ring)
R Clutch Gear Assy. 304305
S Washer (2) 204360
T 84T Gear Assy. 304311
U Clutch Handle Nut 404518
V Clutch Spring Keeper 204721
W “O”-Ring 204770
X Brake Spring Replacement Kit 5703160
Ref. Part Number
Y Screw, 1/4-20x7/8" (3) 205242
Z Clutch Spring 204711
AA Spacer (3) 404513
AB Front Plate 404495
AE Nut, 10-32 Locknut (2) 205193
AF Brake Disc Assy. 304422
AG Screw, 1/4-20x3/8" (4) 205337
AH 12T Pinion Gear 404522
A “E” Ring 205135
AK Base Spacer 404510
AL Reel Shaft 404514
AM Retaining Ring 204468
AN Screw, 1/4x20x1/2" (2) 205189
AP Washer (2) 205109
AR Reel Assy. 304815
AV Cover Assy. 304748
AW Cover Plug 204713
AX Clutch Handle 204712
AY Screw – #4x1/2 205196
AZ Strap (2" x 20') 5242516
BA Base Shroud – LF 404866
BB Base Shroud – RT 404865
BC Screw (6) 205086
BD Finger Spring Washer 205200
MOTOR PARTS
CA Motor Assy 304742
CB Connector Ass’y 5241518
CC Screw – 1/4x20x3/8 205018
CD Switch 404888
CE Connector 206055
CF Nut – 1/4-20 206225
CG Circuit Breaker Assy 304025
CH Screw, 6-32x7/8" (2) 204959
WIRING DIAGRAM
NEG.
NEG.
POS.
POS.
To order replacement parts contact:
Dutton-Lainson Company
www:dlco.com
Tel: [phone]
ax: 402-460-4612
e-mail: [email protected]
In Europe Contact:
Aqua- arine International Ltd.
8 landers Park
Hedge End, Southampton
Hants, England SO30 2 Z
Tel: [phone]
ax: [phone]
e-mail: [email protected]

FLORIDA
Hagood Brothers Marine
1121 West Church St.
Orlando, L 32805
Tel: [phone]
INDIANA
RG Shamory Enterprises
55625 Currant Road
Mishawaka, IN 46545
Tel: [phone]
NEBRASKA
Dutton-Lainson Company
1601 West 2nd
Hastings, NE 68902
Tel: [phone]
OKLAHO A
Tow Dolly Enterprises
1520 S. Memorial Drive
Tulsa, OK 74112
Tel: [phone]
R
ELECTRIC WINCH SERVICE CENTERS
These authorized centers will be able to supply parts and technical service on all StrongArm®Electric Winches
or warranty claims follow instruction given in “Limited One Year Warranty.”
EC DECLARATION OF CONFOR ITY
Dutton-Lainson Company, Hastings, NE 68902-0729 U.S.A. manufactures and declares that this winch is in conformity with the
essential health and safety requirements specified in The Supply of Machinery (Safety) Regulations 1992 and the provisions of the
Machinery Directive (89/392/EEC). This declaration does not apply to other machinery using this winch.
WINCH DATE CODE:
(LOCATED INSIDE FRA E AT REAR)
WINCH ODEL NU BER:
DATE PURCHASED:
NOTES