Warrior Winches 8000 Quick reference guide

ELECTRICAL WINCH
8000 / 8000-SR
Assembly & Operating Instructions

INTRODUCTION
Congratulations on your purchase of a winch. We design and build winches to strict
specifications and with proper use and maintenance should bring you years of
satisfying service.
WARNING - Read, study and follow all instructions before operating this
device. Failure to heed these instructions may result in personal injury
and/or property damage.
Your winch can develop tremendous pulling forces and if used unsafely or
improperly could result in property damage, serious injury or death. Throughout
this manual you will find the following symbols for caution, warning and danger.
Pay particular attention to the notes preceded by these symbols as they are written
for your safety. Ultimately, safe operation of this device rests with you, the operator.
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. This notation is also used to alert against unsafe
practices.
Indicates a potentially hazardous situation which, if not avoided
could result in death or serious injury.
1
CAUTION
WARNING

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GETTING TO KNOW YOUR WINCH
Your 8000lb winch is a powerful piece of machinery. It is important that you
understand the basics of its operation and specifications so that when you
need to use it, you can use it with confidence and safety. Below is a list of
the components of your winch and their use. Practices using your winch
before you are in a situation to need to use it.
1. Motor: Your 4.6hpmotor is powered by a 12 volt battery and providespower to the gear
mechanism which turns the drum and winds the wire rope;
2. Winch Drum: The winch drum is the cylinder on which the wire rope is stored. It can
feed or wind the rope depending on the remote winch switch.
3. Wire Rope: Your winch has a 21/64"X65.6' galvanized aircraft cable designed
specifically for load capacity of 8000lbs. The wire rope feeds onto the drum in the “under
wind” position through the roller fairlead and is looped at the end to accept the clevis
hook pin.
4. Roller Fairlead: When using the winch at an angle the roller fairlead acts to guide the
wire rope onto the drum and minimizes damage to the wire rope from abrasion on the
winch mount or bumper.
5. Mechanic Gear System: The reduction gears convert the winch motor power into
extreme pulling forces.
6. Braking System: Braking action is automatically applied to the winch drum when the
winch motor is stopped and there is a load on the wire rope. The braking action is
applied by a separate mechanical brake.
7. Free Spooling Clutch: The clutch allows the operator to manually disengage (“Out”) the
spooling drum from the gear train, free spool. Engaging the clutch (“In”) locks the winch
into the gear system.
8. Solenoid: Power from the vehicle battery flows through the weather sealed switch
before being directed to the winch motor.
9. Remote Switch: The Power switch lead has a dual switch for powering in or powering
out your winch drum. The Power switch leads allow you to stand clear of the wire rope
when the winch is under load.
10.Wireless Remote Control: allow you control winch far from 50 Ft away.

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11.Universal Flat Bed Mounting Channel: Your winch has been optional
supplied with a flat bed mounting channel that can be mounted to most
flat surfaces such as trailers, stepbumpers, truck beds, etc. Themounting
channel also has holes to accept your roller fairlead.
12.Snatch Block: If Your winch were supplied with a snatch block that, used
properly, can double the pulling power of winch, or change your pulling
direction without damaging the wire rope. We recommend you to use
double line and snatch block for pulling over 85% related line pull.
WINCH ASSEMBLY AND MOUNTING
8000lbs:
1. Your 8000lb winch is designed with a bolt pattern that is standard in this class of
winch. Many winch mounting kits are available that utilize this bolt pattern for the

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most popular vehicle and mounting channels. If you cannot find a kit locally,
contact us and we will provide you with the name of a dealer near you. If you will
utilize the mounting channel you must ensure that it is mounted on a flat surface
so that the three major sections (motor, drum and gear housing) are properly
aligned. Proper alignment of the winch will allow even distribution of the full rated
load.
2. Start by connecting the Roller Fairlead (Part# 800700) to the Mounting Channel
(Part# 800025) using 2 each of the Cap BoltM10 X 35 (Part# 800002), FlatWasher
(Part# 800004), Lock Washer (Part# 800003) and securing with M10 Nut(Part#
800024) (Make sure the bolt is placed through the mounting channel and roller
fairlead from inside the channel. This will allow enough clearance for the winch to
be placed in the channel without obstruction.)
3. Assemble the winch to the Mounting Channel (Part# 800025) by first pulling and
releasing the clutch knob to “Off” position (Free Spooling). Pull out a few inches
of cable from the drum and feed the wire loop through the opening in the front of
the mounting channel and roller fairlead. Now, using the remaining M10 x 35 Cap
Bolts (Part# 800002), Flat Washer (Part# 800004), Lock Washer (Part# 800003)
and M10 Nut (Part# 800005) secure the winch to the mounting channel.
4. Connect the battery and motor leads as the drawing above every type of winch is
different each other.
CAUTION –Batteries contain gases which are flammable and explosive.
Wear eye protection during installation and remove all jewelry. Do not lean over
battery while making connections.
5. Assemble the Clevis Hook to the cable. Take off the pin from the Clevis Hook,
connect the Clevis Hook to the cable and mount the pin back to the Clevis Hook.
6. Always use the Hand Saver when free-spooling and re-spooling the wire rope.
Using the Hand Saver keeps your hands and fingers away from the rotating drum.
7. Check for proper drum rotation. Pull and turn the clutch knob to the “off” position
(Free-spooling). Pull out some cable from the drum, and then turn the clutch knob
to the “In” position to engage the gears. Press the cable out button on the power
switch. If the drum is turning and releasing more cable then your connections are

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accurate. If the drum is turning and collecting more cable then reverse the leads
on the motor. Repeat and check rotation.
SAFETY PRECAUTIONS
WARNING
WARNING –DO NOT EXCEED RATED CAPACITY.
WARNING –Intermittent use only.
WARNING - Do not use winch in lifting or moving or persons.
WARNING - A minimum of five wraps of cable around the drum
barrel is necessary for pulling and holding the rated load. The
cable clamp is not designed to hold the load without 5 wraps of
cable around the barrel.
WARNING - Keep yourself and others a safe distance to the side
of the cable when under tension.
WARNING –The wire rope may break before the motor stalls.
For heavy loads at or near rated capacity, use a pulley
block/snatch block to reduce the load on the wire rope.
WARNING -Never step over a cable, or near a cable under load.
WARNING - Don’t move the vehicle to pull a load (towing) on
the winch cable. This could result in cable breakage.
WARNING-Disconnect the remote control and battery leads
when not in use.
WARNING- Do not exceed maximum pull rating. Avoid “shock
loads” by using the control switch intermittently to take up the
slack in the wire rope. “Shock loads” can far exceed the rate
capacity for the wire rope and drum.

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WARNING- Do not exceeds maximum line pull ratings shown on
the tables.
WARNING-When re-spooling the cable, ensure that the cable
spools in the under-wind position with the cable entering the
drum from the bottom, not the top. To re-spool correctly, and
while wearing gloves, keep a slight load on the cable while
pushing the remote button to draw in the cable. Walk toward the
winch not allowing the cable to slide through your hands. Do not
let your hands get within 12ąof the winch while respooling. Turn
off the winch and repeat the procedure until a few feet of cable
is left. Disconnect the remote control and finish spooling by
hand by rotating the drum by hand with the clutch disengaged.
Keep hands clear of the fairlead and drum while the winch is
under power.
Do not use as a hoist. Do not use for overhead lifting.
Failure to heed these warnings may result in personal injury
and/or property damage.
WARNING - Use gloves to protect hands when handling the
cable. Never let the cable slide through your hands.
WARNING –Never connect the cable back to itself.
Apply blocks to the wheels of the vehicle when on an incline. No
modifications, alterations, or deviation to the winch are
authorized by the manufacturer and SHALL not be made.
Duration of winching pulls should be kept as short as possible. If
the motor becomes uncomfortably hot to the touch, stop winching
immediately and let it cool down for a few minutes. Do not pull for
more than one minute at or near the rated load.

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CAUTION - If the motor stalls do not maintain power to the
winch. Electric winches are designed and made of intermittent use
and should not be used in constant duty applications.
CAUTION - Never release the free-spool clutch when there is a load on the
winch.
CAUTION - Use hand saver hook when handling the hook for spooling or
un-spooling the wire rope.
GENERAL TIPS FOR SAFE OPERATION
xThe 8000lbs and its all derivative types are rated at 8000 lbs capacity
when spooling the first rope layer on the drum. Overloads can
damage the winch/motor/ or wire rope. For loads over 6800 lbs. we
recommend the use of the pulley block/snatch block to double the wire
rope line. The will aid in two ways: a) reduce the number or rope
layers on the drum, as well as, b) reduce the load on the wire rope by
as much as 50%. When doubling the line back to the vehicle, attach
to the frame or other load bearing part.
xThe vehicle engine should be kept running during operation of the winch
to minimize battery drain and maximize power and speed of the
winch. If the winch is used for a considerable time with the engine off
the battery may be drained and too weak to restart the engine
xGet to know your winch before you actually need to use it. We recommend
that you set up a few test runs to familiarize yourself with rigging
techniques, the sounds your winch makes under various loads, the
way the cable spools on the drum, etc.
xInspect the wire rope and equipment before each use. A frayed or
damaged rope shall be replaced immediately. Use only
manufacturer’s identical replacement rope with the exact
specifications.
xInspect the winch installation and bolts to ensure that all bolts are tight
before each operation.
xNever connect the cable back to itself. This will cause cable damage.
Always use a snatch block, sling or chain of suitable strength as
shown in the illustrations.
xStore the remote control inside your vehicle in a place that it will not be
damaged.

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xAny winch that appears to be damaged in any way, is found to be worn,
or operates abnormally SHALL BE REMOVED FROM SERVICE
UNTIL REPAIRED. It is recommended that the necessary repairs be
made by a manufacturer’s authorized repair facility.
xPull only on areas of the vehicle as specified by the vehicle manufacturer.
xOnly attachments and/or adapters supplied by the manufacturer shall be
used.
RIGGING TECHNIQUES
Self Recovery
Locate a suitable anchor such as a strong tree trunk or boulder.
Always use a sling as an anchor point. CAUTION Do not attach
the clevis hook back onto the cable as this could cause damage to
the cable.
As shown in Fig 3.1
Do not winch from an acute angle as the wire rope will pile up
on one side of the drum causing damage to wire rope and the
winch. Fig 3.2
Short pulls from an angle can be used to straighten the vehicle.
Long pulls should be done with the wire rope at a 90° angle to
the winch/vehicle.
When pulling a heavy load, place a blanket or jacket over the
wire rope five or six feet from the hook. In the event of a broken
cable it will dampen the snap back. For additional protection
open the hood of the vehicle as shown in Fig 3.3
For pulls over 6800lbs, we recommend the use of the snatch
block/pulley block to double line the wire rope. Fig 3.4
This reduces the load on the winch and the strain on the rope by
approximately 50%.
Fig 3.1
Fig 3.2
Fig 3.3
Fig 3.4

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WARNING - Never use your winch for overhead
hoisting or for lifting people or moving people.
WINCHING TECHNIQUES A-Z
a. Take time to asses your situation and plan your pull.
b. Put on gloves to protect your hands.
c. Disengage the clutch to allow free-spooling and also save battery power.
d. Attach the hand saver hook to the clevis hook.
e. Pull out the wire rope to your desired anchor point using the hand saver hook.
f. Secure the clevis hook to the anchor point: Sling, chain or snatch block. Do not attach
the hook back onto the wire rope.
g. Engage the clutch.
h. Connect the remote control to the winch.
i. Start your engine to ensure power is being replenished to the battery.
j. Power in the wire rope guiding the wire under tension to draw up the slack in the wire.
Once the wire is under tension stand well clear. Never step over the wire rope.
k. Double check your anchors and make sure all connections are secure.
l. Inspect the wire rope. Make sure there are at least 5 wraps of wire rope around the
winch drum.
m.Drape a blanket or jacket over the wire rope approximately 5 to 6 feet from the hook.
Open the hood for added protection.
n. Clear the area. Make sure all spectators all well back and that no one is directly in front
or behind the vehicle or anchor point.
o. Begin winching. Be sure that the wire rope is winding evenly and tightly around the
drum. The vehicle that is being winched can be slowly driven to add assistance to the
winching process. Avoid shock loads; keep the wire rope under tension.
p. The vehicle to be winched should be placed in neutral and the emergency brake
released. Only release the brake pedal when under full tension. Avoid shock loads to
the winch. This can damage the winch, rope and vehicle.
Fig 3.5

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q. The winch is meant for intermittent use. Under full load with a single line rig do not
power in for more than a minute without letting the motor cool down for a few minutes
and then resume the winching operation.
r. The winching operation is complete once the vehicle is on stable ground and is able to
drive under its own power.
s. Secure the vehicle. Be sure to set the brakes and place the vehicle in park.
t. Release the tension on the wire rope. The winch is not meant to hold the vehicle for
long periods of time.
u. Disconnect the wire rope from the anchor.
v. Rewindthe wire rope. Make sure that any wire already on the drum has spooled tightly
and neatly. If not, draw out the wire and re-spool from the point where the rope is tight.
w.Keep your hands clear of the winch drum and fairlead as the wire rope is being drawn
in.
x. Secure the hook and hook strap.
y. Disconnect the remote control and store in a clean, dry place.
z. Clean and inspect connections and mounting hardware for next winching operation.
MAINTENANCE
1. Periodically check the tightness of mounting bolts and electrical connections.
Remove all dirt or corrosion and always keep clean.
2. Do not attempt to disassemble the gear box. Repairs should be done by the
manufacturer or an authorized repair center.
3. The gear box has been lubricated using a high temperature lithium grease and is
sealed at the factory. No internal lubrication is required.
REPLACING THE WIRE ROPE
1. If the wire rope has become worn or is beginning to show signs of strands breaking,
it must be replaced before being used again. To do this, remove the defective rope
by free spooling. Remove the bolt (Part# 800009) M8x10 on the drum and release
the rope.
2. Insert the end of the new rope and secure the M6 x 10 mm bolt tightly.

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3. Engage the clutch and re-spool the new rope on the drum keeping tension on the
rope as it spools. Ensure that the rope is respooling in the under wind position.
WARNING - Only replace the wire rope with the identical replacement part
recommended by the manufacturer.
TROUBLE SHOOTING
SYMPTOM
POSSIBLE CAUSE
SUGGESTED ACTION
Motor does not
turn on
-Switch Assembly not
connected properly -
Loose battery cable
connections
-Defective Switch
Assembly
-Defective motor
-Water has entered motor
-Insert Switch Assembly all the way into
the connector.
-Tighten nuts on all cable connections.
-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.
Motor runs but
cable drum does
not turn
-Clutch not engaged
-Turn clutch to the “In” position. If problem
persists, a qualified technician needs to
check and repair.
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.
Motor overheating
-Winch running time too
long
-Allow winch to cool down periodically.
Motor runs in one
direction only
-Defective Switch
Assembly
-Loose or corroded battery cable or motor
cable connections. Clean and tighten.
-Repair or replace switch assembly.

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WINCH ASSEMBLY DRAWING

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WINCH PARTS LIST
No.
Part #
Qty
Description
Remark
1
800001
3
Terminal Protect
2
800100
1
Motor Assembly
3
800002
6
Cap Screw M10 x 35
4
800003
6
Lock Washer ĭ10
5
800004
6
Think Flat Washer ĭ10
6
800005
4
Hex Nut M10
7
800200
1
Break / Shaft Assembly
8
800006
2
BushingüDrum
9
800007
2
Tie Bar
10
800008
2
Ring Seals
11
800009
1
Screw M8 x 10
12
800010
4
Lock Washer ĭ8
13
800011
4
Cap Screw M8 x 30
14
800300
1
Drum Assembly
15
800012
8
Screw M5 x 20
16
800013
8
Lock Washer ĭ5
17
800014
1
End Bearing
18
800015
1
Gasket
19
800016
1
GearüRing
20
800400
1
Gear Carrier Assembly˄Output˅
21
800500
1
Gear Carrier Assembly˄Intermediate˅

15
22
800600
1
Gear Carrier Assembly˄Input˅
23
800017
1
GearüInput Sun
24
800018
1
Trust Washer
25
800019
1
GearüHousing
26
800020
1
Clutch Screw
27
800021
1
Ring Seals
28
800022
1
Clutch Cover
29
800023
1
Clutch Handle
30
800024
2
Locknut M10
31
800700
1
Roller Fairlead
32
800025
1
Mounting Channel
By Choice
33
800800
1
Remote Control Switch˄RC3˅
34
800900
1
Cable Assembly
35
801000
1
Control Box
36
800026
2
Screw M5h16
37
800027
2
Lock Washer Ø5
38
800028
2
Block
8000lbs SPECIFICATION
Rated line pulls:
8000 lbs (35.36kN)
Gear reduction ratio:
233:1˄12V˅
Motor: Series Wound ˄Input Power˅
4.6hp / 3.2kW (DC 12V)
Overall dimensions: 21.3" (L) x6.3" (W) x10.2" (H)
540(L) mm X 160 (W) mm X 259 (H) mm
Drum size: Ø2.48" (D) x 8.8" (L)
Ø 63(D) mm ×224(L) mm
Cable: Ø 21/64" (D) x 65.6'(L)
Ø 8.3mm (D) x20m (L)
Weight: 69.7lbs ( 31.6 kgs )
70.5lbs (32kgs )˄-S TYPE˅

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DUTY CYCLE
Line speed and motor current (First layer)
Line pull
Line speed ft/min
(m/min)
Motor current Amps
(Max)
lb (kN)
12V DC
12V DC
0
21.3˄6.5˅
75
2000˄8.89˅
11.5˄3.5˅
160
4000˄17.78˅
10.5˄3.2˅
208
6000˄26.67˅
7.5˄2.3˅
286
8000˄35.56˅
6.6˄2.0˅
320
Line pull and cable capacity
Layer of cable
Rated line pull per Layer lb
(kN)
Cable capacity per Layer ft
(m)
1
8000˄35.36˅
21.3˄6.5˅
2
6620˄29.43˅
46.9˄14.3˅
3
5650˄25.12˅
65.6˄20.0˅
WARRANTY
Your winch has been manufactured and tested to the highest standards. Please
ensure you read and understand the assembly and operating instructions before
use. Failure tocomplywith these instructions or anyimproper use of the equipment
will terminate the warranty.
Please ensure you record the information below:
Distributor
Date of Purchase
Invoice No
Serial No
In the unlikely event you experience problems, contact the distributor with this
information.