trailmaxx WA Series Setup guide

WA Series
Electric Winch
3500lb
Installation and operator’s manual

SAFETY PRECAUTIONS
Warning! Observe safety precautions for personal safety and the safety of others. Improper equipment operation
may cause personal injury and equipment damage.
Read the following carefully before attempting to operate your winch and keep the instructions for future
reference.
1. Dress properly:
Do not wear loose clothing or jewellery; they can be caught in moving parts.
Wear leather gloves when handling winch cable, as broken wires can cause injuries.
Non-slip footwear is recommended.
2. Keep a safe distance:
Ensure that all persons stand well clear of the winch cable and load during winch operation, 1.5
times the cable length is recommended. If a cable pulls loose under load or breaks it can lash
back and cause serious injury.
Do not step over the cable
All visitors and onlookers should be kept well clear of the work area.
Ensure a secure footing and balance while operating the winch.
3. Do not misuse the control cable:
Never carry the winch by the cord, or disconnect it from the receptacle by pulling the cable.
Keep cable away from heat, oil and sharp edges.
4. Do not overwork the winch:
If the motor becomes uncomfortably hot to touch, stop and let it cool for a few minutes.
Do not maintain power to the winch if the motor stalls.
Do not exceed maximum line pull ratings shown in tables, shock loads must not exceed these
ratings.
Any winch showing signs of misuse and/or excessive heat will not be accepted for warranty.
5. Avoid unintentional starting:
Winch clutch should be disengaged when not in use and fully engaged when in use.
Never release the winch clutch while under load.
6. Check for damaged parts:
Before using, you should check your winch carefully. Any part that is damaged should be properly
repaired or replaced by a Trailmaxx authorised service centre.
7. Repairing your winch:
When repairing the winch use only genuine Trailmaxx replacement parts, as using any other
parts will invalidate the warranty and may result in injury to the user.
8. Re-spooling 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 centre as you can.
Walk up, keeping load on the cable as the winch is powered in.
Do not allow the cable to run loosely through your hand and do not approach the winch too
closely.
Turn off the winch and repeat the procedure until all but 1m of cable is in.
Disconnect the remote control switch and finish spooling in the cable by rotating the drum by
hand with the clutch disengaged.
On hidden winches, spool in the cable under power but keep hands clear.

WINCH OPERATION WARNINGS
Read the following carefully before attempting to operate your Trailmaxx winch and keep the instructions for
future reference.
1. The uneven spooling of cable while pulling a load is not a problem, unless there is a cable pile up at one
end of the drum. If this happens reverse the winch to relieve the load and move your anchor point further
to the centre of the vehicle. After the job is done you can unspool and rewind for a neat lay of cable.
2. Store the remote control switch inside your vehicle where it will not be damaged, and always inspect it
before you plug it in.
3. When ready to begin spooling in, plug in the remote control switch with clutch disengaged. Do not engage
the clutch with the motor running.
4. Never connect the hook back to the cable as this causes cable damage. Always use a sling or chain of
suitable length.
5. Keep a close watch on your winch from a safe distance while operating; stop the winch periodically to
check that the cable is not pulling up in a corner. Jamming the cable can break your winch.
6. Do not attach tow hook to winch mounting plate, it must be attached to the vehicle frame.
7. The use of a snatch block will aid recovery operations by providing a doubling of the winch capacity and a
halving of the winch speed, and the means to maintain a direct line pull to the centre of the rollers. When
double loading during stationery winching, the winch tow hook should be attached to the chassis of the
vehicle.
8. Ensure rated “D” or bow shackles are used in conjunction with an approved tree trunk protector to
provide a safe anchor point.
9. When extending the winch cable, ensure that the cable is wrapped at least 5 times around the drum at all
times. Failure to ensure this could result in the cable parting from the drum under load resulting in severe
personal injury and/or damage to property.
10. All Trailmaxx winches are provided with a marking on the cable to indicate when the last 5 turns of cable
are left on the drum. No recovery should be attempted with this mark showing beyond the rollers.
11. Since the greatest pulling power is achieved on the innermost layer of your winch, it is desirable to pull off
as much line as possible for heavy pulls (You must leave at least 5 turns on the drum). If this is not
practical use a snatch block and double line arrangement.
12. Draping a heavy blanket or similar object over the extended winch cable is recommended as it will
dampen any backlash should a failure occur.
13. Neat, tight spooling avoids cable binding, which is caused when a load is applied and the cable is pinched
between the other coils. If this happens, alternatively power the winch in and out; do not attempt to work
a bound cable under load, free by hand.

14. Apply blocks to wheels when vehicles are on an incline.
15. Battery:
Be sure that the battery is in good condition. Avoid contact with the battery acid and other
contaminants.
Always wear eye protection when working around a battery.
Have the engine running when using the winch to avoid draining the battery.
16. 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 (230kgs)
or the outer wraps will draw into the inner wraps and severely damage the cable during
winching. The first winch run should be a familiarisation run while in a relaxed, non-recovery
situation. Spool out the cable until the cable mark appears, then rewind the cable on the drum
under a load of 500lbs (230kgs) or more. This will slightly stretch and tension 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 loctite or an equal compound to the cable clamp
thread. Tighten the clamp screw properly but do not over tighten. The loctite will prevent
loosening of the screw in arduous conditions. Loctite 7471 primer and 222 threadlocker are
recommended.
17. Do not attempt to exceed the pulling limits of this winch
18. Do not drive your vehicle to assist the winch in any way. Vehicle movement in combination with winch
operation may overload the cable, the winch itself or cause damaging shock loads.
19. Shock loads when winching are dangerous! A shock load occurs when an increase in force is suddenly
applied to the cable. A vehicle rolling back on a slack cable may induce a damaging shock load.
20. The winches shown in this manual are solely for vehicle and boat mounted non-industrial applications.
21. Do not use the winch in hoisting as these winches do not conform to the required hoist safety factors and
features.
22. Do not use the winch to lift, support or otherwise transport personnel.

INSTALLATION
Mounting your winch
Mount the winch on the vehicle using the M8 x 30 bolts and spring washers provided. The winch must be mounted
in position with the cable spooling off the bottom of the reel not the top. Improper mounting could damage your
winch and void the Trailmaxx warranty.
Lubrication Installation
All moving parts in the winch are permanently lubricated with high temperature lithium grease at time of
assembly. Lubricate cable periodically using light penetrating oil. Inspect cable for broken strands regularly and
replace if necessary. If the cable becomes worn or damaged it must be replaced. Do not replace cable with a cable
which is rated lower than the original.
Electrical connection
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 the battery fully charged.
1.1. Connect the red motor terminal to the red motor connection terminal on the control box using a red
cable.
1.2. Connect the black or white motor terminal to the black motor connection terminal on the control box
using a black cable.
1.3. Connect the red power cord terminal on the control box to the positive (+) terminal on the battery using
a red cable.
1.4. Connect the black power cord terminal on the control box to the negative (-) terminal on the battery
using a black cable.
1.5. Check the direction of drum rotation. Turn the clutch knob to the “OFF” position and free spool some
cable off the drum. Turn the clutch knob to the “IN” position and push the “IN” button on the controller,
if the cable respools this is correct, if not swop the battery leads over and recheck.
Wireless control
Your Trailmaxx winch is installed with a wireless control unit housed in the control box. This unit should have an
operating range of at least 10 meters. If problems are experienced with the wireless control it may be of benefit to
open the control box, locate the wireless control unit attached to the inside of the case, locate the aerial (green
wire attached only at one end) and feed it out through the bottom of the control box into a more exposed
position. To further extend the performance of the wireless control a Trailmaxx booster aerial can also be fitted.

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
recognise the sound of a light steady pull, a heavy pull, and sounds caused by the load jerking or shifting. Soon you
will gain confidence in operating your winch and its use will become second nature to you.
Operating
1) Ensure the vehicle is secure by applying the park brake or chocking the wheels.
2) Pull out the winch cable to the desired length and connect to the anchor point. The winch clutch allows rapid
uncoiling of the cable for hooking onto the load or the anchor point. The shifter tab located on the gear
housing of the winch operates the clutch as follows:
a) To disengage the clutch, move the clutch shifter tab into the “OUT” position. Cable may not be free
spooled off the drum.
b) To engage the clutch, move the clutch shifter tab into the “IN” position. The winch is now ready for
pulling.
3) Recheck all cable rigging before proceeding.
4) Plug in the winch hand control. It is recommended that the winching operation takes place from the driver’s
position to ensure safe operation.
5) To commence winching operation, start the vehicle engine, select neutral in the transmission, and maintain
engine speed at idle.
6) Operate the remote control switch in or out until the vehicle or load has been retrieved. Regularly check the
winch to ensure cable is winding onto the drum evenly.
Note
1) Never winch with your vehicle in gear as this could damage the transmission.
2) Never wrap the cable around the object and hook onto the cable itself. This can cause damage to the object
being pulled, and may kink or fray the cable.
3) Keep hands, clothing, hair and jewellery clear of the drum area and cable when winching.
4) Never use the winch if the cable is frayed, kinked or damaged.
5) 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 brake, it can suddenly whip back towards the winch, causing serious injury to anyone
in the area. Always stand well to the side when winching.
6) Do not leave the switch plugged in while not in use.
CHECK THE WINCH CAREFULLY AND THOROUGHLY BEFORE OPERATING!

Performance specifications
WA35 –12v 3500lb ATV Winch
Performance/Specifications
Single line rated pull
3500lb/1591kg
Gearing
3 stage planetary
Motor
Permanent Magnet 12v DC, 1.1hp
Gear Reduction ratio
136:1
Cable
4.8mm x 15.2m
Clutch
Freespooling, cam activated
Overall Dimensions (mm)
335L x 110W x 112H
Weight
Line Speed and Current Drain - Based on first layer on drum
Line Pull lb/kg
0
500lb/227kg
1000lb/454kg
2500lb/1134kg
3500lb/1581kg
Line Speed (mpm)
8.3
6.1
4.9
2.1
1.3
Current Drain
15
40
60
160
210
Line Pull Capacity –Based on first layer on drum
Cable Layer
1
2
3
4
5
Rated Line Pull per Layer
3500lb/1363kg
2561lb/1164kg
2234lb/1015kg
1981lb/900kg
1779lb/808kg
Total rope on drum
2.7m
5.86m
9.48m
13.58m
15.2m
MAINTENANCE
It is highly recommended that the winch be used regularly (at least once a month). Simply power out the cable
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 authorised Trailmaxx outlet for technical assistance and
repairs.
NOTE:
The safety precautions and instructions discussed in this manual cannot cover all possible
conditions and situations that may occur. It must be understood by the operator that
common sense and caution are features which cannot be built into this product, and must be
supplied by the operator. accepts no liability for any consequences of using this
product if not used in accord with this manual.

Other quality brands
Call 0800 MAXX11, Email: [e-mail] or visit our website
www.trailmaxx.co.nz for more information.