TUNGSTEN T Series Setup guide

TUNGSTEN T series ATV winch
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Installation and Operator’s manual for
Tungsten ATV/UTV winch
As you read these instructions, you will see WARNINGS, CAUTIONS, NOTICES and NOTES.
Each message has a specific purpose. For your safety, obey all safety tips. Non-compliance
with safety tips can lead to serious injury or damage. Read these instructions carefully
before using your winch. Keep this book close to the winch to read it at any time.

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Contents:
1. Safety Warnings & Precautions ……….….………….…………….…..……………...........03
2. Winch mounting & Assembly
(1) Mounting Winch ……………….….……………………………………………………….06
(2) Mounting the Contactor ……………...………………………………………………………….06
(3) Mounting Remote Control ……………………….….……………………………………….07
(4) Electrical Connection……………………………………………………………………….…...08
(5) Checking the system ……………………………..…………………………………………….09
3. Maintenance & troubleshooting ………………………………………………..…………….09
4. Winch Assembly Drawing ……………..…………………………………………………………11
5. Specification …………………………………………………………………………………………...12
6. TUNGSTEN Winch Packing List……………………………..……..…………………………...13
7. Warranty Information ………………………………………………………………………………14

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1. Safety Warnings & Precautions
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death.
To avoid injury to hands or fingers:
• Always keep hands clear of rope, hook loop, hook and fairlead opening during installation,
operation and when spooling in or out.
• Always use supplied hook strap whenever spooling rope in or out, during installation, and
during operation.
• Always wear heavy leather gloves when handling rope.
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to minor or moderate injury.
• Always keep wired remote control lead clear of the drum, rope and rigging. Inspect for
cracks, pinches, frayed wires or loose connections. Replace remote control if damaged.
• Always pass wired remote control through a window to avoid pinching lead in door, when
using remote inside a vehicle.
• Never leave remote control where it can be activated during free spooling, rigging, or when
the winch is not being used.
• Always require operator and bystanders to be aware of vehicle and or load.
General Safety:
• Always know your winch. Take time to fully read the Installation Guide and the Basic Guide
to Winching Techniques in order to understand your winch and its operation.
• Never operate this winch if you are under 16 years of age.
• Never operate this winch when under the influence of drugs, alcohol or medication.
• Never exceed winch or rope capacity listed on product data sheet. Double line using a
snatch block to reduce winch load.
Installation Safety:
• Always choose a mounting location that is sufficiently strong to withstand the maximum
pulling capacity of your winch.
• Always use factory approved mounting hardware, components, and accessories.
• Always use grade 5 (grade 8.8 metric) or better mounting hardware.
• Never weld mounting bolts.
• Always use carefully when using longer bolts than those supplied from factory. Bolts that
are too long can damage the base and/or prevent the winch from being mounted securely.
• Always mount the winch and attach the hook to the rope’s end loop before connecting the
electrical wiring.
• Always position fairlead with WARNING label on top.

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MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to minor or moderate injury.
• Always spool the rope onto the drum in the direction specified by the winch warning label
on the winch and/or documentation. This is required for the automatic brake (if so equipped)
to function properly.
• Always prestretch wire rope and respool under load before use. Tightly wound wire rope
reduces chances of “binding”, which can damage the rope.
• Always inspect, rope, hook, and slings before operating winch. Frayed, kinked or damaged
rope must be replaced immediately. Damaged components must be replaced before
operation. Protect parts from damage.
• Never leave remote control plugged into winch when free spooling, rigging, or when the
winch is not being used.
• Never hook rope back onto itself. In this case it cause rope be damaged.
• Always use a choker chain, choker rope, or tree trunk protector on the anchor.
• Always be certain the anchor you select will with stand the load and the strap or chain will
not slip.
• Never engage or disengage clutch if winch is under load, rope is in tension or drum is
moving.
• Always select an anchor point as far away as possible. This will provide the winch with its
greatest pulling power.
• Never winch with less than 5 wraps of rope around the drum. The rope could come loose
from the drum.
• Never touch rope or hook while in tension or under load.
• Never use winch to secure a load.
• Always use a hook with a latch
• Always insure hook latch is closed and not supporting load.
• Never use winch to lift or move persons.
• Never use winch as a hoist or to suspend a load.
AVOID WINCH AND EQUIPMENT DAMAGE
• Always avoid side pulls which can pile up rope at one end of the drum. This can damage
rope or winch.
• Always ensure the clutch is fully engaged or disengaged.
• Never use winch to tow other vehicles or objects. Shock loads can momentarily exceed
capacity of rope and winch.
• Always avoid “powering out” for extended distances. This causes excess heat and wear on
the winch motor and brake.
• Always use carefully to protect the vehicle frame when anchoring to a vehicle during a

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winching operation.
• Never “jog” rope under load. Shock loads can momentarily exceed capacity of rope and
winch.
• Never use winch to secure a load during transport.
• Never submerge winch in water.
• Always store the remote control in a protected, clean, dry area.
• Always double line or pick distant anchor point when rigging. This maximizes pulling power
and avoids overloading the winch.
To prevent accidental activation of the winch and serious injury, complete the winch
installation and attach the hook before installing the wiring.
Safety
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. For specifications and
performance data, refer to the specification sheet supplied with your winch.
2. Winch mounting & Assembly
Figure 1: To install the
complete kit, you will
need to mount the
winch, contactor
handlebar mounted
Mini-rocker switch and
remote socket.

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Step (1) - Mounting the Winch (Figure 2)
Figure 2: Orientation of winch to
mounting plate and bolt lengths.
To secure the winch, always use:
• A flat, secure mounting location at least 4.8 mm (3/16
in.) thick.
• Lock washers.
• Hex head cap screws when using a one-piece winch
mount plate.
Note: When using separate winch mount and fairlead
plates use hex head cap screws on the motor side of
the base as shown in Figure 2.
• Torque the mounting bolts to 16 N-m (12 lb-ft)
• Remove bottom tie bolt. This bolt should be retained
for winch service.
• Attach the clevis hook to the wire rope.
• Put clutch in freespool position.
• Manually feed cable loop through fairlead.
• Attach hook to cable loop and re-engage clutch.
Step (2) - Mounting the Contactor (Figure 3)
Figure 3. Contactor for
ATV winch
• The contactor is a primary safety feature in your winch system.
It disconnects your winch from its power source when the ATV
is not in use. The contactor must be correctly installed to work
properly.
• It is recommended that the contactor be mounted close to the
battery and in a location that is as clean and dry as possible.
Exact location will vary, depending on the ATV. Usual locations
include inside, on top, or on the side of rear storage box, and
on a few models, under the seat.
• Ensure the contactor mounting location selected provides sufficient clearance from all
metal structures such as frame tubes. Do NOT place tools or other items in a position that
might come in contact with the contactor directly.
• Drill the mounting holes for the contactor at this time, then move on to step four as it will be
easier to attach all the wiring to the contactor before attaching it to the ATV. Do NOT mount
the contactor at this time.
• If you will be installing the TUNGSTEN wireless control, first review the wiring configuration
provided here.

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Step (3)- Mounting the Remote Control (Figure 4 -7)
TO PREVENT SERIOUS INJURY OR DEATH FROM ELECTRICAL FIRE:
• Do NOT route electrical cables across sharp edges.
• Do NOT route electrical cables through or near moving parts.
• Do NOT route electrical cables through or near any high heat parts.
• Avoid pinch and wear/abrasion points when installing all electrical cables.
TO AVOID INJURY AND PROPERTY DAMAGE:
• Use caution when moving or repositioning any vehicle controls so as to not compromise
the safe operation of the ATV. Select a mounting position that will provide clearance for all
vehicle controls.
• Before securing the switch cable with tie wraps, make sure that the handlebars have full
range of motion.
Figure 4: handlebar mount. Figure 5: Mini-rocker switch assembly
Exact positioning may vary depending on ATV make and model.
• It is recommended that the switch be installed on the left handlebar. A piece of electrical
tape around the handlebar will help prevent rotation of mount on the handle bar.
• Do NOT tighten over any 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 wire to a key controlled accessory
circuit of the ATV (use the provided wire splice). Using a test light (figure 6), locate a suitable
wire from the ATV key switch. The wire should only have power when the key is in the "ON"
position.
Figure 6: Use a test light to locate a suitable wire

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Figure 7:
Remote socket installation.
TO PREVENT SERIOUS
INJURY OR DEATH FROM
EXPLOSION:
• Do NOT drill into gas tank.
• Verify the area is clear behind the mounting location
before drilling.
• After determining the mounting location for the
remote socket, drill three holes and install. (Figure 7)
• Once the remote socket is mounted, route the two
bullet terminal wires back to where the contactor will
be mounted. Splice the end of the red wire to a key
controlled accessory circuit of the ATV (use the
provided wire splice). 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.
NOTE: If installing both switches, both red wires
MUST be spliced to a key controlled accessory
circuit of the ATV as described above.
Step (4) – Electrical Connection (Figure 8)
Place the supplied terminal boots on wires before securing to the contactor. All wires must
be attached to the contactor before mounting the contactor to the ATV.
• Connect red cable one terminal (“M+”) of contactor to terminal positive (+) of the motor.
• Connect black cable one terminal (“M-“) of contactor to terminal negative (-) of the motor.
• Connect red cable one terminal (“B+”) of contactor to terminal positive (+) of the battery.
• Connect black cable one terminal (“B-“) of contactor to terminal negative (-) of the battery.
Figure 8: Wiring
Installation diagram
• If installing both the
handle bar switch and
the remote socket, first
attach the terminals on
the green and black
remote socket wires into
the contactor (green to
green, black to black), or
connect the red cable of
remote socket to the
terminal (marked “B+” )
of the contactor .

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• Always remove jewelry and
wear eye protection.
• Never lean over battery
while making connections.
• Always verify area is clear of
fuel lines, fuel tank, brake
lines, electrical wires, etc.
when drilling.
• Never route electrical cables:
- Across any sharp edges.
- Through or near moving parts.
- Near parts that become hot.
• Always insulate and protect all exposed wiring and electrical terminals.
• Always install terminal boots as directed in installation instructions.
Step (5) - Checking the System (Figure 9)
Figure 9
Before using the winch, verify the
following:
• Wiring to all components is correct. All loose
wires are tie wrapped tight.
• There are no exposed wiring or terminals.
Cover any existing terminal exposures with
terminal boots, heat shrink tubing or electricians
tape.
• Turn ATV key switch to ON position. Check
winch for proper operation. The wire rope should
spool in and out in the direction indicated on the
switch.
3. Winch Maintenance and Trouble Shooting:
 Winch Maintenance
 No further internal lubrication is required for the life of the winch . The winch should
not submerge in water (waterproof winch should not be soaked in water for a long
time). If the winch is submerged in water by accident, you should remove the earth

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bolt on the bottom of the motor and remove water as soon as possible. You should
use the winch within 3 days, to help remove water from winch motor parts
 Lubricate the cable periodically, to replace a new cable as soon as possible if it glitch
occurs, fracture, and creases.
 You should clean and lubricate after using; Also should store the winch in the dry and
drain place, disengage the clutch, and avoid children to contact and play.
 Each assembly or connection screw is loosen, or corrosion , please repair and replace
timely
 Troubleshooting
NO. SYMPTOM POSSIBLE SUGGESTED
1 Motor does
not turn on
- Switch Assembly
not connected
property
- Loose battery
cable Connections
- Solenoid
malfunctioning
- Defective Switch
Assembly
- Defective motor
-Water has entered
motor
- Insert Switch Assembly all the way
into the connector.
- Tighten nuts on all cable connections.
- Tap solenoid to loosen contacts.
Apply 12volts to coil terminals directly A
clicking indicates proper activation.
- Replace Switch Assembly
- Check for voltage at armature port
with Switch pressed. If voltage is
present replace motor.
- Allow to drain and dry. Run in short
bursts without load until completely dry.
2 Motor rotates
but Cable
drum does
not turn
- clutch not
engaged
-Move clutch to the” in” position. If
problem persists, a qualified technician
needs to check and repair.
3 Motor runs
slowly or
without
normal
power
Insufficient current
or voltage
- Battery weak, recharge. Run winch
with vehicle motor running.
- Loose or corroded battery cable
connections. Clean ,tighten, or replace
4 Motor runs
too hot
- Long period of
operation
-Let winch cool down periodically
5 Winch runs in
one direction
only
- Defective or stuck
solenoid
- Defective Switch
Assembly
- Tap solenoid to loosen contacts.
- Repair or replace solenoid.
- Replace Switch Assembly