Superwinch H14W User manual

Fitting Instructions
Kit Nos. 6760, 6760V, 7590
MECHANICALLY
POWERED
DRUM
WINCHES

FittingInstructions
Kit Nos. 6760,6760V, 7590
These instructions coverkits from
18/11/1997
01 INTRODUCTION
02 GENERAL SPECIFICATION DATA
03 LUBRICANTS, FLUIDS & CAPACITIES
INSTALLATION
04 WINCH, BUMPER BAR & ROLLER FAIRLEAD
05 BUMP STOP SPACER
06 STEERINGDAMPER BRACKET
07 POWER TAKE OFF
08 SHAFTING
09 NOTES ON EXHAUST CLEARANCE
COMMISSIONINGAND USE
10 SETTING & ADJUSTING THE SYSTEM
11 FITTINGTHE ROPE
12 TESTING & OPERATING INSTRUCTIONS
13 RUNNING IN,MAINTENANCE &SERVICING
14 ASSEMBLY DRAWINGS
SuperwinchLtd.,
Abbey Rise, WhitchurchRoad,Tavistock,Devon.
GreatBritain.
PL19 9DR
([phone]
2+44(0)1822615204
:[e-mail]
Superwinch Inc.,
Winch Drive,Putnam,Connecticut06260
U.S.A.
([phone]
2(860) 928 1143
:www.superwinch.com
i

01-1 INTRODUCTION
INTRODUCTION
Thank you for purchasing a Superwinch. Ithas been
designed and manufactured to provide yearsof trouble-
freeoperation. Pleaseread andunderstandthese Fitting
Instructions beforeusingyourwinch.Your winch isa
very powerfulmachine.If used unsafely or improperly,
there isa possibilitythat property damage or personal
injurycan result.We have included severalunique
featuresin the winch to minimize this possibility,
however, yoursafety ultimately depends on your caution
when usingthe product.Correctinstallation ofyour winch
is a requirement for correct operation. Pay particular
attentionto theinstallation sectioninthese Instructions.
Congratulations onyour choice.
Superwinchreserve therighttoalter model specifications
without prior notice.
PLEASE KEEP THESE INSTRUCTIONS AND THE
TORQUE ADAPTOR WITH THE WINCH.
Theseinstructions are designed to assist skilled
technicians in theefficient installation of aSuperwinch,
using the appropriate trade tools.
WARNINGS,CAUTIONS AND NOTES
Theseare giventhroughthese instructionsin the
following form :
WARNING: Procedures whichmust be
followedpreciselyinorder toavoidthe
possibility of personal injury.
CAUTION : This calls attentiontoprocedures
whichmust be followedtoavoiddamageto
components.
NOTE : This calls attentiontomethodswhich
make a jobeasieror gives helpful
information.
SUPERWINCHwinches are not to be used to lift,support
or otherwise transport personnel. Any such useshall be
consideredto invalidatethe warrantyandSuperwinch
shallnot be responsiblefor any claims arisingfromsuch
use.
REFERENCES
References to theleftand right hand side inthe
instructions are made when viewing the vehiclefrom the
rear.
REPAIRSAND REPLACEMENTS
Before youcontact Superwinch oryour nearest Dealer
please have ready the following information:
Kit No.
SerialNo.ofwinch
Part No. required
POISONOUS SUBSTANCES
Many liquids andothersubstances usedshould under no
circumstancesbe consumed, andshould be keptaway
fromopenwounds. These substances include (among
others) hydraulic oil.
SYNTHETIC RUBBER
Many ‘O’ringseals, flexible pipesandsimilaritems,
whensubjectedto fire or heat canbecome highly
corrosive. Handle with seamless industrial gloves only.
Shouldskincontactoccur, remove contaminatedclothing
immediatelyandobtainmedicalassistance without delay.
Meanwhile, wash the affected area with copious amounts
of coldwateror limewater for 15 to 60 minutes.
RECYCLING AND THEENVIRONMENT
Itis illegal to disposeof used oil in theground, down
sewers or drains orinto waterways.
Dispose of used oil through authorised waste disposal
contractors. If indoubtcontactyour local Authority for
adviceondisposal facilities.
GENERAL DESCRIPTION
These instructions outlinefittingofan H14Wdrum winch
andmechanical PTOonto aLand Rover Ninety, One-
Ten, 127,4 Cylinder or V8.
Pleasereadandunderstandthese instructions before
fittingthe winch. Correctinstallationof the winch has a
direct affect on correctoperationof thewinch.Ifyoudon't
fully understand any sectioninthese instructionsit isa
good idea toread through againbeforecommencing
fitting.Make any notes as you read for additionalsundry
items notincluded in the kit.
Pleaseensureallitems listedonthese pages are
included in the package youreceivefrom us. Ifany items
are missing, please contact our customer services
department.
INTRODUCTION
01

02-1
GENERALSPECIFICATION DATA
WINCH
Type .......................................................................H14W (drum)
Gear Reduction ......................................................Worm wheel
Wormbox ratio .......................................................48 : 1
Drum ......................................................................Fabricatedsteel mountedonmaintenance free plainbearings
Drum capacity ..............ø9mm (5/16”) ................77 M(253’)
ø10mm (3/8”) .................. 54M(177’)
ø11mm (7/16”) ................ 46M(151’)
Braking...................................................................Irreversible worm and wheel
Freespool...............................................................Manualrelease
Safe Working Load(bottom layer) .........................8000lbs
Line Speed .............................................................Fullyvariable, 14 M /min (46’ /min) outerrope layer
......... 8M /min (26’ / min) innerrope layer
Weight .......................... Frontassembly ...............48.08 kg(106lb)
P.T.O.............................. 12.24kg (27 lb)
Bumper ...........................24.29 kg (54lb)
Shafting ..........................7.50kg (17 lb)
GENERAL SPECIFICATION DATA 0
2

03-1 LUBRICANTS,FLUIDS & CAPACITIES
PTO LUBRICANTOIL
Fill PTOtolevelplug with the same oil as usedinthe
vehicletransfer box (consult Land Rover workshop
manualsforspecifications). The PTOis fitted withtwo
plugs, theupper oneisthe level plug,and thelower one
is the drainplug. Lubricategreasenipples on PTO
shaftingusing lithium based EP grease.
LUBRICANTS,FLUIDS & CAPACITIES
03
LEVEL PLUG
DRAIN PLUG

OVERVIEW
In thissection we will fitthe bumper /winch /roller
fairlead to thevehicle.
110/127 4 cylenginedvehicles: Itisrecommended to
fit heavy duty suspension springs on thefrontaxle of the
vehicle. The springs,LandRoverPartNo.s NRC9448
(drivers side) and NRC 9449 (passengers side) are
availablefrom anyMain Landrover Parts dealer. These
should be fitted to thevehicle in accordance with the
Land Rover workshopmanual.
Now,identify the parts inthe followingassembly.
INSTALLATION OFWINCH, BUMPER BAR&
ROLLER FAIRLEAD
Removeexistingvehiclebumper,bumper fixing plates
and retaining clips (fittedtobumperbottommounting
plate) Fitfixing plates and retainingclips to bumper bar /
winch mount.
Make sure the chassismembers, where the bumper bar
fits,areclean. Smearwithgrease,topand bottom.
Make sure couplingis securely fitted to winch.
Sincethe winch and bumperare quiteheavy, itis a good
idea to place the assembly onto abox about12”high, in
front ofthe vehicle.It isalso advisabletohave someone
to help you with the next stage.
Fit twonut plates(Item 5)into theends of thechassis
members aligning withthe holesin thebottom ofthe
chassis member.
Fit the bumperbar / winch / roller fairleadassembly (Item
4)tothe front of the vehiclein the same position as the
originalbumper bar.Inspectthe original bumper boltsfor
damage, andreplace ifnecessary. Place the bolts and
washers(Item 2)in positionandloosely tighten. Fit two
M10 x 25bolts (Item 1)in the undersideof the jacking
bracketwith plainandspringwashers(Items 2&3).
Tightenwinch basemountingbolts.
Tightenallbumper barbolts.
Fit vehicle number plate to frontof bumperbar /winch
mount.
WINCH /BUMPER BAR /ROLLER FAIRLEAD INSTALLATION 0
4
04-1
WINCH / BUMPER BAR /ROLLER FAIRLEAD INSTALLATION
BUMPER /WINCHMOUNT KIT
Part No.7310
ITEM QTY PARTNo. DESCRIPTION
1 2 4.33.1002522 BOLT M10x 25
2 6 4.50.1023 PLAINWASHER M10
3 2 4.51.1023 SPRING WASHER M10
4 1 SEE ASSEMBLY DRAWINGS BUMPER BAR /WINCH/ROLLER FAIRLEAD
5 2 70-52034 NUT PLATE

05-1 BUMP STOP SPACER INSTALLATION
OVERVIEW
Inthis sectionwe willfit the Bump Stop Spacer.Thiswill
helpthe shaftingto avoid hitting the axle whentravelling
offroad. Identify the partsin thefollowingkit :
INSTALLATION OFBUMP STOP SPACER
Remove the rubberbump stopfrom the front lefthand
side of the vehicle in accordance with theLandRover
workshop manual.
Place theSpacer between therubber bumpstop and the
vehiclechassis and secure itinto position in accordance
with the LandRoverworkshop manualusingthe nuts,
spring washers, plain washers and longerset screws
provided.
BUMP STOP SPACER INSTALLATION
05
BUMP STOP SPACER KIT
Part No.70-90194
ITEM QTY PART No. DESCRIPTION
6 2 4-32-0805022 SETSCREW M8 x50
7 2 4-47-0823 NUTM8
8 2 4-50-0833 PLAIN WASHER M8
9 2 4-51-0823 SPRING WASHER M8
10 1 70-20060 BUMP STOP SPACER (LH)
11 1 9365 FITTING INSTRUCTIONS

06-1
STEERING DAMPER BRACKETINSTALLATION
STEERINGDAMPER BRACKET INSTALLATION 0
6
OVERVIEW
In thissection we will fitthe SteeringDamperBracket.
Firstthough, identify the parts in thefollowing assembly.
PTOSHAFTKIT(Foruse on 90/110/127 TDiDefenderV.I.N.939976 onward)
Part No.70-90028V
ITEM QTY PART No. DESCRIPTION
12 1 4-32-1402512 SETSCREWM14 x25
13 2 4-33-0803022 BOLT,M8x 30
14 6 4-33-0802522 BOLT,M8X 25
15 1 70-90208 EXHAUST CLAMP SUPPORT ASS'Y
16 1 70-90207 EXHAUST CLAMP ASS'Y
17 1 70-90202 MOUNTBRACKETASS'Y
18 1 70-90201 BRACKET,SUMP ASSY
19 1 70-90275 FRONTSHAFTASSY
20 1 70-50331 SHAFT,REAR
21 1 4-47-1423 NUT, M14
22 1 4-51-1413 SPRINGWASHER M14
23 2 4-50-1413 PLAIN WASHER M14
24 12 4-51-0823 SPRINGWASHER,M8
25 12 4-50-0823 WASHER,M8
26 6 4-47-0813 NUT, M8
27 2 4-50-0623 WASHER,M6
28 2 4-51-0613 SPRINGWASHER,M6
29 2 4-47-0613 NUT, M6
30 1 4-150-002 BOX,WOODEN
31 4 128 KEY
32 1 244 UNIVERSAL JOINT
33 12 245 SOCKETSET SCREW1/4" BSF
34 1 277 UNIVERSAL JOINT,TURNED
35 1 284 SELF ALIGNING FLANGEBEARING
36 1 797A POLYTHENE BAG
37 1 6384 BEARINGLOCATION PLATE
38 1 6766 SELF ALIGNING FLANGEBEARING
39 1 6782 STEERING DAMPERBRACKET
40 1 70-50414 HEXAGON STUB SHAFT
41 1 6863 UNIVERSAL JOINT (BROACHED)
42 1 7212 BEARINGLOCATION BRACKET
43 2 4-40-050503 SKTSETSCREWM5 x 5
44 2 7222 SKTSETSCREW
1 5-030-001 CHECK LIST

STEERING DAMPER BRACKETINSTALLATION
06-2
PTO SHAFTKIT (For useon90/110/127Defender 4 cyl (inc.TDi)up to V.I.N.939976)
PartNo. 70-90028
ITEM QTY PARTNo. DESCRIPTION
45 1 4-32-1402512 BOLTM14x 25
46 2 4-33-0809022 BOLTM8 x 90
47 2 4-33-0807022 BOLTM8 x 70
48 1 4-32-0805022 SETSCREW M8 x 50
49 4 4-32-0803512 SOCKETSETSCREWM8 x 35
50 8 4-33-0802022 BOLT,M8 x20
51 1 70-90027 COUPLING SHAFT
52 4 4-60-084003 RIVNUTM8
53 1 70-60063 BRACKETR.H.
54 1 70-60062 BRACKETL.H.
55 1 4-47-1423 NUT,M14
56 1 4-51-1413 SPRING WASHER M14
57 2 4-50-1413 PLAIN WASHER M14
58 14 4-51-0823 SPRING WASHER, M8
59 18 4-50-0823 WASHER, M8
60 6 4-47-0813 NUT,M8
61 4 4-50-0623 WASHER, M6
62 4 4-51-0613 SPRING WASHER, M6
63 4 4-47-0613 NUT,M6
64 7 128 KEY
65 3 244 UNIVERSAL JOINT
66 16 245 SOCKETSETSCREW1/4" BSF
67 1 797A POLYTHENE BAG
68 2 6384 BEARING LOCATION PLATE
69 3 6766 SELFALIGNINGFLANGEBEARING
70 1 6782 STEERINGDAMPER BRACKET
71 1 6854 HEXAGONSTUB SHAFT
72 1 6941 UNIVERSAL JOINT(BROACHED)
73 1 8122 SHAFT,REAR
74 1 8127 BRACKET,REAR ASSEMBLY
75 1 8784 EXHAUSTMANIFOLD SEAL
76 1 10515 INTERMEDIATESHAFT
77 1 10518 FRONT SHAFTASSY
78 1 10521 BRACKET,SUMP ASSY
79 2 10522 SPACER
80 6 4-40-050503 SKTSETSCREWM5 x5

06-3
STEERINGDAMPER BRACKET INSTALLATION
Fit steering damper bracketto existingdamperbracket
onchassis, using M14x 25 (Item90) setscrew,twoplain
washers(Item 91),spring washer (Item 90) andnut(Item
89) as shown below.Refitthe steeringdamper to the
lower hole in thesteeringdamperbracket.
STEERING DAMPER BRACKETINSTALLATION
PTO SHAFTKIT(Foruse on V8models)
Part No.70-90038
ITEM QTY PART No. DESCRIPTION
81 1 4-32-1402512 SETSCREWM14 x 25
82 1 4-32-0805022 SETSCREWM8 x 50
83 4 4-32-0803512 SETSCREWM8 x 35
84 6 4-33-0802512 BOLT,M8 x 25
85 1 70-90027 COUPLING SHAFTASSY
86 4 4-60-084003 RIVNUTM8
87 1 70-60063 BRACKETR.H.
88 1 70-60062 BRACKETL.H.
89 1 4-47-1423 NUT,M14
90 1 4-51-1413 SPRING WASHER M14
91 2 4-50-1413 PLAIN WASHER M14
92 12 4-50-0823 PLAIN WASHER M8
93 6 4-47-0823 NUT,M8
94 12 4-51-0823 SPRING WASHER, M8
95 6 128 KEY
96 1 244 UNIVERSAL JOINT
97 1 267 UNIVERSAL JOINT
98 1 284 FLANGED BEARING
99 1 797A POLYTHENEBAG
100 1 6766 SELFALIGNING FLANGE BEARING
101 1 6782 STEERINGDAMPER BRACKET
102 1 6854 HEXAGON STUB SHAFT
103 1 6863 UNIVERSAL JOINT
104 1 7185 BEARINGBRACKETASSEMBLY
105 1 7210 FRONTSHAFTASSEMBLY
106 1 7211 SHAFT,REAR
107 1 7212 BEARINGLOCATION PLATE
108 12 245 SKTSET SCREW,1/4" BSF
109 2 7221 BOLT,5/16" UNCx 1" LONG
110 2 4-40-050503 SKTSET SCREWM5 x 5
111 2 7222 SKTSET SCREW
Steering Damper Bracket (Item18)

07-1 POWER TAKEOFFINSTALLATION
POWER TAKE OFFINSTALLATION
07
OVERVIEW
Here we will fitthe Mechanical Power Take Off.Identify
theparts in the following assemblies:
POWER TAKE OFFINSTALLATION
From inside the vehicle remove the vehiclefront centre
seat squabandcover panel.Remove transfer box rear
cover plate.Thecover and existing bolts will not be
required.Make sure the face of the transfer box is clean
and freefrom oldgasket,oil, grime etc.Fit gasket(Item
124) toPTO.FitPTO to transfer boxand secure with
M10 x 45 bolts (Item115) and spring washers (Item 117).
P.T.O.FITTINGKIT
Part No. 7726
ITEM QTY PART No. DESCRIPTION
112 3 4.50.0723 WASHER
113 1 213 LOCK NUT
114 1 214 CONTROL KNOB
115 4 4.33.1004512 BOLT M10 x 45
116 2 4.33.1004012 BOLT M10 x 40
117 6 4.51.1013 SPRINGWASHER M10
118 6 4.63.151223 SPLITPIN
119 1 4.123.1533 GROMMET
120 6 5190 SPIGOTBUSH
121 1 6438 LINKROD
122 1 6467 OPERATINGSHAFT
123 1 6743 TORQUE ADAPTOR
124 1 6770 GASKET
125 3 785 CLEVISPIN
POWER TAKE OFF
Part No. 6440
ITEM QTY PART No. DESCRIPTION
126 1 6440 POWER TAKE OFF
Transfer Box rear cover plate
Transfer Box

07-2
POWER TAKE OFFINSTALLATION
Drill one holeø19mm(3/4") through theheelboard.
Deburr hole and fitgrommet(Item 119).Pushoperating
shaft(Item 122) through thegrommet(frominsidethe
centre seataccess hole). Fitlinkrod (Item 121) to PTO
using clevis pin(Item125), washer (Item112) and split
pin (Item118). Fit operating shaft to linkrod using clevis
pin (Item125), washers (Item 112) and split pins (Item
118).Fit7/16" BSFlocknut (Item113) and knob (Item
114) to operating shaft.
Fit key(Item 31) andUniversal Joint (Item 32) to Power
Take Off(bottomend).
P.T.O.Unit P.T.O.
P.T.O. Operating knob
Heelboard
Universal Joint (Item32)
Key(Item 31) P.T.O.
Transfer
Box
TorqueAdaptor (Item 123)
Cover
Key
P.T.O.Unit

08-1 SETTING& ADJUSTINGTHE PTO
SETTING& ADJUSTINGTHEPTO
08
SETTINGAND ADJUSTING THE PTO
With theengine turned off, engage first gear and PTO
(by pullingthe knob towards the frontofthe vehicle),
slidethe torqueadaptor supplied (Item 123) ontoPTO
output shaft.Using a 20mmA/Fsocket onthe torque
adaptor, check thetorque reading.
Adjustment:remove the red cover from the rear ofthe
PTO unit,loosen setscrewinround nut(Item 171).Insert
a ø8mm barinto theplain holeinthe round nut.Turnthe
adjustingnutwith the bar, clockwiseto increase torque
(increase linepull) and anti-clockwise to decrease torque
(lower linepull).
Torque iscorrectwhenthe steelballs in the PTOsnap
out ofengagement.Output shaftwillturn approximately
one third ofa turn, thenthe ballswillsnapinto
engagement.TightenM10 setscrew and replacecover.
TypicalTorque Settings
(anti-clockwise)
RopeDia Min breaking Max torquesetting Max linepull
(mm) load (lbs) (lbsft) bottom
layer(lbf)
13 23,968 80 8000
11 17,180 75 7400
9 11,513 60 6000
It should be noted thatthemethod of setting the linepull
quoted is very approximate. The final linepull may be
±15%.
To set the linepull with themaximum accuracy a
loadcellshould be employed on a fullyrun in
winch. Ifthe torque isset before the winch is runinthen
thelinepull will increaseuntilthe winch becomes runin.

09-1
SHAFTING INSTALLATION
SHAFTINGINSTALLATION 0
9
OVERVIEW
Refer toprevious sections for parts
SHAFTINGINSTALLATION
All vehiclesexcept TDi V.I.N. 939967 onwards :
Assemble self-aligning bearing(100) to brackets (88&
87) with M8 x 25 bolts (84) noting thatthe bearingsslots
inthe brackets are offset towards thebearing. Position
assembly underNo.2 crossmember as shown,using the
couplingshaftbetweenthe winch and thebearing. This
will position the brackets under thecrossmember.Ensure
the coupling shaft is inline with the winch drive coupling.
Mark the positionof 4 holes inthe underside ofthe
crossmember.Remove assembly.Drill 4 holesdia
10.6mm.Fitrivnuts as shown.
Fit leftand right handbracket assemblyto crossmember.
4Cylindermodels only :
Fit the rear mountbracketassembly to underside of
gearbox,usingthe twoexisting tapped holes as shown.
Secure with M8 x 20bolts, plainandspringwashers.
Fit the sumpassembly bracketto theengine sump
flange,usingspacers as required, bolts and washers.
The bracketis fitted to thefront of thesump flange.
NOTE :On Defender 4 cylupto V.I.N. 939976 vehicles,
the sump bracket fits to the FRONT of the sump, not the
side,usingspacers to clear thepower steeringpump.
Fit the relevant shafting kit as shown on theprevious
pages.
NOTE: Attention should be given to the following points ;
There shouldbe a gap of 12mm between thefront shaft
and the universaljoint (at the hexagonslidingjoint to
allow forengine movement.
Use adjustments at the sump bracketassembly to obtain
the maximumclearancebetweenthe frontaxle and the
winch shafting.
90/110/127 TDi DefenderV.I.N. 939976 onwards :
The rear bracket and bearingshould be fixedinto
position after the sump bracket assembly haslocated the
shaftinit's correct position.

SHAFTINGINSTALLATION
09-2
Front (sump) mountbracket assembly on V.I.N.939967onwards vehicles
Rear mount bracket assemblyon V.I.N. 939967 onwards vehicles

10-1
NOTESONEXHAUSTCLEARANCE
NOTES ON EXHAUST CLEARANCE 1
0
NOTES ON EXHAUST CLEARANCE
On some vehicles, thereis limited room between the
Engine sumpandthe ExhaustDownpipe, where the PTO
shafting is sited.To create extra clearance it may be
necessary tore-positionthe exhaust downpipe,if your
vehicle is fittedwith an exhaust clamp approximately
150mm(6") below the manifold,removetwo bolts and
clamp bar, clamping Down Pipe and loosenthe fixing to
the manifold, loosen fixings atrear end ofdownpipe *,fit
down pipe seat as shown and refitbut donottighten two
boltsand clampingbar.Starting at the manifold, refit the
exhaustdown pipeleaving the tightening of the clamp
bar to last.
*NOTE : Itisadvisable to fitthenew exhaustmanifold
sealsupplied.
Ifyour vehicle is not fitted with an exhaust clamp, support
the down pipewith a block ofwoodbetweenthe down
pipe and thechassis and GENTLY lever the lowerpart of
the down pipeaway from the sumpas shown.
NOTE : Whilst levering thedownpipe itis importantto
take special care notto damage the downpipe or sump
casingetc.
NinetyNon-Turbocharged vehicles (with oval main
silencer) :
Slackennuts onthe exhaust clampat the rear ofthe tail
pipe and at the flange where thedown pipe meets the
exhaustmanifold. Cutoffthewelded bracket on the main
silencer.Turn the main silencer end to endand turn
vertically, using clamp bracket.
Fit extensionbracket to forwardsilencer supportas
shown.Check front pipe and tail pipeclearances and
tighten allexhaustconnections.
TDi V.I.N. No.939976ONWARDS
Remove exhaustbracket infrontof mainsilencer box,
replace with suppliedexhaustclamp support assembly
(70-90208). Fit exhaustclamp assembly (70-90207) to
exhaust pipe. Slacken exhaust fixingsto gain exhaust
movementbefore refitting exhaust hanger rubber. When
exhaust is in position tighten all exhaust fittings.
Ninety TurboDiesel vehicles NOT TDi(with round
mainsilencer) : ModKit 8891
Remove the rear exhaustpipeassemblyand main
silencer box. Fitthe front tubeassembly (Item 128)and
exhaust olive (Item129) using M8 x45 bolts (Item131),
plainandspringwashers (Items 133 &134) supplied,
and looselyrefitthe mainsilencer box using the original
fittings.
Cutacross the rear exhaustpipeassembly
Exhaust ModificationKit
Part No.8991
ITEM QTY PARTNo. DESCRIPTION
127 1 8822 Rear Adaptor
128 1 8825 FrontTubeAssembly
129 1 8889 Olive
130 1 8824 Clamp
131 3 4-33-0804522 Bolt M8 x 45
132 3 4-47-0823 Nut M8
133 3 4-51-0823 Spring Washer M8
134 3 4-50-0823 PlainWasher M8

approximately 260mm (10.23”) from theflangeand
square tothe pipe as shown. Remove therubber
mounting and mounting bracket fromthe pipe bracket.
Ensure that the new endof the rear pipe is square and
de-burred,looselyfitadaptor pipe(Item 127) to end of
existing rear pipe to ensure correctfitting.Dis-assemble
thetwo pieces againandremove any grease, soot etc.
from thejoint areas.
Slide the exhaust clamp (Item 130) over therearpipe.
Smear exhaust jointingcompound onthe joining area of
therearpipeand rejoin the two pieces in their
approximate position, ensuring thatthe new pipe is atthe
correctangleto theoriginal pipesection (this may be
compared with theangle ofthe 260mmsection removed)
Fitthe hangingbracket to the new section of rearpipe.
Place the modified rear pipe in position and twistthetwo
sections ofrear pipe as necessaryto ensure correct
alignment and clearance with the groundandthe vehicle
underbody.
Locate and fix the exhaust brackets andtighten allnuts
andbolts.
Ninety TDivehicles :
Remove thecompete centresection ofexhaust pipe and
refit the new pipe supplied.
NOTESON EXHAUSTCLEARANCE
10-2

11-1
FITTINGTHE ROPE
FITTINGTHE ROPE 1
1
FITTINGTHE ROPE
Slackenoffthe Socket setscrew on the winch drumand
turn thedrum so that the screwisuppermost.Unwind the
ropeandlay ina straight line on the ground.
NEVER wind theropeonto thedrumfroma coil.
Disengagethe drum drive by pulling back the safety
interlockhandle and pulling thefreespoolhandle towards
the drum ofthewinch.Theropedrum should now rotate
freely. If it does not, rotate thedrum until itdoes.
Facing the winch, feed thetaperedendinto the slot
between the upperandlower roller on the rollerfairlead
and under theropedrum. Insert the tapered end (from
the rear) intothe cross-drilled hole,keepingthe rope end
inside thedrum core diameter.
Tighten theset screw onto therope. Re-engagethe rope
drumby pulling the freespool handle away from the drum
untilthe safety interlock handle keeps it inposition.Ifthe
handle willnotturn enough, rotate thedrum slightly until
the handle canbeturned sufficiently.
Starttheengine,engagethe P.T.O.and, while keeping a
tensiononthe rope, startwinching in, taking care to coil
the rope neatly ontothe drum with coils tight against
each other.
Caretaken atthis stage willprolong the life of
the rope.
Runthe rope back untilabout two feetonly remain. ease
offonthe controllever onthe wing, and carefully stow
the hook into the lugonthe winch frame or intothe back
ofthebumper. Lightly tightenupthe slack to ensure that
the hook does not slipfree when on themove.
Then :
IMPORTANT :
DisengageP.T.O.
Engage the transfer gear required.
Note :Normallythe winch freespool handleisleft inthe
“engage” position topreventaccidental spillage of rope
when the winchis not inuse.

12-1 TESTINGAND OPERATING INSTRUCTIONS
TESTINGAND OPERATING INSTRUCTIONS
12
TESTINGAND OPERATING INSTRUCTIONS
WINCHINGPROCEDURE
Whereverpossible,pointvehicledirectly at load to obtain
even cable lay on drum.
Putboth vehicle gearboxlever and transfer box lever
into neutral. Engagethe PTOby moving thehorizontal
lever fully forward. The PTOengagement lever protrudes
from theseat box under the centre seat.
Engage reverse gear to releasealltension(or load)in
thewire rope.
Ensure gear lever isreturned to neutral position.
Pull safety interlock pin outandmove freespool lever
towards drum(FREE).
IMPORTANT
Ensure there is no load on thewire ropebefore
operatingFreespool Handle.
Haulout rope and secure to load.
Re-engage freespool -apply light pressure tofreespool
handle whilst slowly rotating thedrumby pulling outthe
cable by hand.
Ensure lever snaps inandsafetyinterlock is fully
engaged before proceeding(ENGAGED).
IMPORTANT
The Winch Freespool must NEVERbedisengaged when
winchinginor out.
Engage a forward gear andcarefullytake upthe slack
cable.
Using the throttle,keep theengineat afasttickover-
1000/1200 rpmand commence winching. Max. speed
forthe winch is 1500 rpm.
Note : Allgears can be used, 2nd gear is usually better
forheavy loads.
To securewinchafteruse, wind slackrope onto drum, using
PAY-ON LEVER toensure evenlay.
KEEP HANDSAND FINGERS CLEAR OF
WINCH ROPE AND HOOK WHEN OPERATING
WINCH. Neverput your finger throughthe hook when
reeling inthe lastfewfeet.Ifyour finger should become
trapped in the hookorrope,you couldlose your finger.
UsetheHANDSAVERBARto guidethehookforthe
lastfew feet. Never guide awirerope under tension
onto the drum withyour hand.
Secure hook instowagepositionand tightenrope.
Disengage P.T.O. The freespool handle on the winch
shouldremaininthe engaged position to prevent
unwinding of ropewhilst driving.
OVERLOAD PROTECTION
The overloaddevicefittedtothis P.T.O. isafully
automatic torque limiter. Whenan overload condition is
reached,an audibleclicking willbeheardcomingfrom
underthecentre seat. Whenthis clickingisheard,the
clutch pedal must be depressedimmediately. Thewinch
isfully self sustaining andwill notreleasetheload.
Engage reverse gear,to release tensionin the ropeIfit
isobvious that theloadisat maximum, reposition
vehicle,or use apulleysystem(snatch block). Re-
engagethegearusedin winching,recommence
winching.
IMPORTANT
Thiswinchshould NEVER be used for lifting or moving
personnel.