TRAVELLER 2500 User manual

Tractor SupplyCompany
R0
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2500lb.Winch
UserManual&OperatingInstructions
PerformanceSpecifications
MaxLinePull
2500lbs.(1134kgs)
Gearreductionratio
170:1
Motor
PermanentmagnetDC12Vmotorwith1.1hp output
Overall Dimensions
12.7in.(323mm)L 4.45in.(113mm)W 4.4in.(112 mm)H
Drumsize
1.46in.(37mm)D 3.15in.(80mm)L
Cable
45.9ft.(14.0m)L of3/16in.(4.8mm)D
Netweight
21.7lbs.(9.86kgs)
ProductOverview
This winchis equippedwithapermanent magnet motorandis designedfor
intermittent dutygeneraluse.This winchis not tobeused forindustriallifting or
movingpeople. Improperoperation could damagethe winchand voidthewarranty.
Free spoolclutch is operated bya pulland turn knob, which disengagesthe gearbox,
allowingthe cable to bereleased.

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INSTALLATION
Correct installation ofthewinch isrequired forproperoperation.
lMount thewinchonthe mountingchannelbyusingascrew(M8 16mm)(foursets).
lMount thewinchwiththe mountingchannelonthe vehicle orotherfixed
installation byusing a screw(M8 1.25 35mm), M8 nut, Φ8flat washerand Φ8
springwasher(two sets).
WARNING: Thiswinchmust bemountedwith thecablein anunderwound direction.
Impropermounting coulddamagethewinchand voidthe warranty.
Connect the red wiretothepositiveterminaland theblackwire to thenegative
terminalofthebattery.(See Fig.1).
Fig. 1
lCheck therotation direction ofthedrum. Pullandturnthe clutch knobto the
“FREE SPOOL”position (drumshouldturn freelybyhand). Pullout some cable
fromthedrum, and then turntheclutchknob to the “ENGAGE”position. Pressthe
“OUT”button on the ATV/UTVswitch;ifthecableisreleasing then it is properly
connected. Otherwisereverse thewire connectionsto themotor, and repeatthe
above-mentioned operation.

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TheATVmounting
TheUTVmounting
Removethescrews Removethelid
Takeofftheswitch
Dashboard
Puttheswitchin

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OPERATION
lPulland turnthe clutch knob, sothe drumcan turn freelybyhand.
lUse hand saverbartohitch thehookofthecableassemblyand pullcable to the
load.Attachthe cablehooktothe load.
WARNING: Check thatthere areat least fiveturnsofcableremaining on the drum
beforeoperation. Ensure theclutchknob isinthe engagedposition.
CAUTION: Clutch must befullyengaged beforewinching.
Neveroperatethe clutchwhiledrum is turning. Do notreadjust clutchknobasit has
beenadjustedandpermanentlylockedinplacewith a thread-locking compound in the
factory.
lPressthe “IN”button on the ATV/UTVswitchtore-spoolthe cable. Pressthe
“OUT”button to reversedirections.Wait untilthemotorstopsbefore reversing
directions.
lRe-spoolthecableaftercompletingtheoperation.
REPLACINGTHECABLE
lEngagethe clutch byturningtheclutchknobto the “ENGAGE”position.
lWheninserting thecable into thedrum, insertitintothecorrectend of the hole
provided.Tighten thescrews.
lOperate thewinch an re-spoolthecable around the drumtightly.
CAUTION: Tokeep thestatedtension, besurethe cable is wrappedon thedrum
tightly.
WARNING: Alwaysreplacedamagedcablewith manufacturer’sidentical
replacementpart.

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MAINTENANCE
lPeriodicallychecktightness ofmounting boltsandelectricalconnections.Remove
allthedirtorcorrosionand alwayskeepclean.
lDo notattempt to disassemblethegearbox. Repairsshouldbedone bythe
manufacturerorauthorizedrepaircenter.
lThegearboxhasbeenlubricatedusinghightemperaturelithiumgrease inthe
factory.Nointernallubrication isrequired except whenbeing repaired.
TROUBLESHOOTING
SYMPTOM POSSIBLECAUSE SUGGESTEDACTION
Motor does not
turnon
-SwitchAssemblynot
connected properly -Insertswitchassemblyall thewayinto the connector.
-Loose batterycable
connections -Tightennuts on allcable connections.
-Defectiveswitch
assembly -Replaceswitchassembly.
-Defectivemotor -Check forvoltageat armatureportwithSwitch
pressed. Ifvoltageispresent,replace motor.
-Waterhasentered
motor -Allow to drainand dry.Runinshortbursts without loaduntilcompletelydry.
Motorruns but
cable drumdoes
not turn -Clutchnotengaged -Turnclutchtothe “In”position. Ifproblem
persists, aqualifiedtechnicianneeds tocheck
and repair.
Motorruns
slowlyor without
normalpower
-Insufficient currentor
voltage
-Batteryweak recharge. Run winchwith vehicle
motorrunning.
-Loose or corrodedbatterycable connections.
Clean, tighten,orreplace.
Motor
overheating -Winch running time toolong -Allow winch to cool downperiodically.
Motorruns in
onedirection
only
-Loose or corroded
batterycableor motor
cableconnections. -Clean andtighten.

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WINCH ASSEMBLY
17
2
3
18
16
15
13 14
12
10
789
5
4
6
8
3
1
2
11
30
8
30
28 29
19 20 21
22
23
24
25
26
27
35
34
36
31 32 33
37
33
32 31
41
38
39
40

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WINCH PART LIST(2500LBS)
No. Part # Qty Description
1 P0250100 1 MotorAssembly
2 P0250001 4 Locking Washer Φ8
3 P0250002 4 Cap ScrewM8x16
4 P0250003 1 Transition Shaft
5 P0250004 2 Tie Bar
6 P0250005 1 HexagonalShaft
7 P0250006 1 FrontBush Drum
8 P0250007 6 SpringWasher Φ6
9 P0250008 1 ScrewM6 x8
10 P0250009 2 Cap ScrewM6x70
11 P0250010 1 Drum
12 P0250011 1 RearBushDrum
13 P0250012 1 FrontThrustWasher
14 P0250013 1 GearRing Output
15 P0250200 1 GearCarrierAssembly
16 P0250014 1 GearRing
17 P0250015 1 ThrustWasher
18 P0250016 1 GearHousing/EndBearing
19 P0250017 1 BearingHolder
20 P0250018 1 RollerBearing
21 P0250019 1 Clutchaxes
22 P0250020 1 CamClutch Gear
23 P0250021 1 Spring
24 P0250022 1 CoverClutchHousing
25 P0250023 1 RollerBearing
26 P0250024 1 ElasticCollar
27 P0250025 1 ClutchHandle
28 P0250026 1 Locking Washer Φ5
29 P0250027 1 Cap ScrewM5x12
30 P0250028 4 Cap ScrewM6x25
31 P0250029 4 HexFlangeNut M8
32 P0250030 4 Locking Washer Φ8
33 P0250031 4 ThickFlat Washer Φ8
34 P0250300 1 RollerFairlead
35 P0250032 1 Mounting Channel
36 P0250033 2 Cap ScrewM8x20
37 P0250034 2 Cap ScrewM8x35
38 P0250035 1 Strap
39 P0250400 1 Cable Assembly
40 P0250036 2 TerminalProtector
41 P0250500 1 ControlAssembly

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SAFETYPRECAUTIONS
lNeverlift people orhoistloadsoverpeople. Do notliftitemsvertically, this winch
isdesigned forhorizontaluse only.
lNeveroverload.Be sure allequipment usedmeetsthewinch’smaximumlinepull
rating. Whendouble-lining,pulleyblocks should beratedforaminimumoftwo
timesthewinch’slinepullrating.
lDo notattempt prolongedpulls withheavyloads. Theelectricwinch is designed
forintermittent useonly, and shouldnotbe usedin aconstant dutyapplication.
Neverpull formore than one minute orexceedtheratedload.If the winchmotor
becomeshot tothe touch,stop thewinch andallowitto cooldownforseveral
minutes.
lNeveroperatewinchwithlessthan 5 turnsofcable around thewinch drumsince
the cableendmaynot withstandfullload.
lAvoid continuouspulls fromextremeanglesbecause this will cause thecableto
gatheron oneend ofthedrumanddamage thecable.Be aware that thewinch’s
linepullcapacityis themaxline pullofthe firstlayer.Neveroperate winchpulling
a loadthat exceedsthe rated capacity.
lNeverhookthecableback to itself because itcoulddamagethe cable.
lBe surethewinchismountedsecurelyon thevehicleorbracket before operation.
lBeforemovinga load,inspect the cable. Prevent kinksandunevencablelayer
before theyoccur. Applypropertension to loadsunder100lbs.
lDo notmoveyourvehicletoassistthewinch in pullingthe load.It willbeeasyto
overload,andcausecabledamage. Beawareofthe dangerzone.Keepaway
fromthedangerzone during theoperation.Thedangerzone istheareaofthe
winchdrum, thefairlead (iffitted), thecable,thepulleyblock(ifused),the hook,
and themotor.

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lNeverapproachorspan thecablewhen the winch isunderload.
lWhenusingthewinchtomove a load, placethe vehicle transmission inneutral,
setvehicle brake, andchock allwheels.Thevehicle engineshouldbe running
duringwinchoperation so thatbatteryhasfullyelectricity.Neverusethewinch
when thereisalack ofvoltage.
lNeverdisconnectfreespoolcultchwhenthere is a load onthe winch.
lAlwaysstand clearofthe cable, hookandwinch. Youshould disconnect the clutch
first, thenusethehand saverbartohitch the hooktopullthe cable.
lInspectwinch,cable,hooks andotheraccessoriesfrequently.Afrayed cablewith
brokenstrandsshouldbereplacedimmediately.Useheavyleathergloveswhen
handlingthe cable. Do notlet thecableslide throughyourhands.Inspect the
cable beforeuse. Mashed , pinched, frayedorkinkedareasseverelyreduce the
load-carrying capability.Replacement cablesmust bere-spooled under100lbs.
lTokeep stated tensile,re-spoolthe cable aroundthe drumtightlyafteroperation.
lDo notoperatewinchwhen underthe influence ofdrugs,alcoholormedication.
Alwaysstayalertduringoperation.
lWeareye protectionandpersonalprotectiveequipment while operatingwinch.
lForloadsover50%ofratedlinepull, theuseof the pulleyblock/snatch block to
doublethe cable is recommended.
lDo notoperate aroundpotentiallyflammableliquids, gases,ordebris.Sparks
mayoccur,resultingin theignition offire.

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Linespeed andMotorcurrent(Firstlayer)
LinePull LineSpeed
ft./min (m/min) MotorCurrent Amps
Ibs.(kgs) 12VDC 12VDC
0 14.1(4.3) 20
500(227) 9.8(3.0) 55
1500(680) 7.5(2.3) 95
2500(1134) 4.3(1.3) 160
LinePullAndCableCapacity
Layer Rated line pulllbs(kgs) Totalropeon thedrum ft (m)
1 2500(1134) 6.9(2.1)
2 2033(922) 15.1(4.6)
3 1713(777) 24.3(7.4)
4 1480(671) 34.1(10.4)
5 1303(591) 45.9(14.0)
DistributedBy:
TRACTOR SUPPLYCOMPANY
5401VIRGINIAWAY,
BRENTWOOD, TN37027
Forcustomersupport,call:1-888-376-9601
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