Warrior Winches S4000EN Quick reference guide

ELECTRICAL WINCH
S4000EN
Assembly & Operating Instructions

CONTENTS
INTRODUCTION....................................................................................... 1
GETTING TO KNOW YOUR WINCH ....................................................... 2
SAFETY PRECAUTIONS......................................................................... 3
GENERAL TIPS FOR SAFE OPERATION.............................................. 5
WINCHING TECHNIQUES A-Z....................................................................6
WINCH ASSEMBLY AND MOUNTING.................................................... 7
MOUNTING DRAWING............................................................................ 9
WINCH ACCESSORIES YOU WILL NEED ............................................. 9
RIGGING TECHNIQUES.......................................................................... 9
WINCH WORKING DEMONSTRATION.................................................1 0
REPLACING THE WIRE ROPE..............................................................1 1
MAINTENANCE......................................................................................1 1
TROUBLE SHOOTING...........................................................................1 2
WINCH ASSEMBLY DRAWING S4000EN ............................................1 3
WINCH PARTS LIST S4000EN..............................................................1 4
SPECIFICATION.....................................................................................1 5

INTRODUCTION
Congratulations on your purchase of a high quality winch.
We design and build
winches to strict specifications and with proper use and maintenance will bring you
years of satisfying service.
WARNING - Read, study and follow all instructions before operating this
winch.
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.
This indicates a potentially hazardous situation, which if not avoided, may
result in minor or moderate injury. This notation is also used to alert you
against unsafe practices.
This indicates a potentially hazardous situation, which if not avoided,could
result in death or serious injury.
1
WARNING
CAUTION

GETTING TO KNOW YOUR WINCH
Your 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. You should practice using
your winch before you are in a situation where you need to use it.
1.
This winch is engineered for maximum line pull with only one layer of cable
spooled onto the winch drum (the first layer).
Motor: Your 7.1hp/7.9hp motor is powered by a 12/24 volt battery and provides
power to the gear mechanism which turns the drum and winds the wire rope;
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.
Wire Rope (cable): Your winch has a 15/32"X87' galvanized aircraft cable
designed specifically for load capacity of 17500lbs. 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.
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.
Mechanic Gear System: The reduction gears convert the winch motor power
into extreme pulling forces.
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. A
separate mechanical brake applies the braking action.
Free Spooling Clutch: The clutch allows the operator to manually disengage
(“CLUTCH OUT”) the spooling drum from the gear train, free spool. Engaging
the clutch (“CLUTCH IN”) locks the winch into the gear system.
Solenoid: Power from the vehicle battery flows through the weather-sealed
switch before being directed to the winch motor.
2.
3.
4.
5.
6.
7.
8.
9.
10. Remote Switch: The Power switch leads have 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.
2

11.Wireless Remote Control: allow you control winch up to 50 Ft away.
12.Universal Flat Bed Mounting Channel: Your winch could have been optionally
supplied with a flat bed mounting channel that can be mounted to most flat
surfaces such as trailers, step bumpers, truck beds, etc. The mounting channel
also has holes to accept your roller fairlead.
13.Snatch Block: If Your winch is supplied with a snatch block that can double the
pulling power of the winch, or change the pulling direction without damaging the
wire rope. We recommend you to use double line and snatch block for pulling
over 70% of the rated line pull.
SAFETY PRECAUTIONS
WARNING
WARNING –Do not exceed rated capacity shown in this table.
WARNING –Intermittent use only. Allow winch to cool between uses.
WARNING - Do not use winch to lift (vertically).
WARNING - Do not use winch to pull or move people in any way.
WARNING –NEVER cut, weld, or modify any part of the winch or cable.
WARNING - A minimum of five wraps of cable around the drum barrel
necessary for pulling and holding the rated load.
is
WARNING - Keep yourself and others a safe distance to the side of the cable
when it is under tension.
3
Layer
Rated line pull lbs (kgs)
Total rope on the drum ft (m)
1
17500（7938）
18.0（6.0）
2
14140（6414）
40.7（13.0）
3
11862（5381）
65.9（21.0）
4
10217（4634）
86.9（26.5）

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 go near a cable under load (in tension).
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 or always isolate
winch when not in use.
WARNING- 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.
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 spool correctly you should 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
12 ″ of the winch while re-spooling.
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.
WARNING - Do not use as a hoist. Do not use for overhead lifting.
WARNING - 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. 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.
4

CAUTION - If the motor stalls do not maintain power to the winch. Electric
winches are designed and made for intermittent use and should not be used in
constant duty applications.
CAUTION - Never disengage the clutch when there is a load on the winch.
CAUTION –Use the hand saver hook when handling the hook for spooling or
un-spooling the wire rope.
GENERAL TIPS FOR SAFE OPERATION
•
The 4000KGS and its all derivative types are rated at 4000KGS capacitywhen
spooling the first rope layer on the drum. Overloading can damage the
winch/motor/ or wire rope.
For loads over 70% of rated line pull. we
recommend the use of the pulley block/snatch block to double the wire rope
line. This 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.
The 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 amount of time with the engine off the battery
may be drained and too weak to restart the engine.
Get 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.
Inspect the wire rope and equipment before each use. A frayed or damaged
•
•
•
rope must be replaced immediately.
Use only the manufacturer’s identical
replacement rope with the exact specifications.
Inspect the winch installation and bolts to ensure that all bolts are tight before
each operation.
•
5

•
Never 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.
Store the remote control inside your vehicle in a place that it will not be
damaged.
Any winch that appears to be damaged in any way, is found to be worn, or
operates abnormally shall be removed from service.
Pull only on parts of the vehicle as specified by the vehicle manufacturer.
Only attachments and/or adapters supplied by the manufacturer shall be used.
Whenever before your winch start to working, please slightly test-run your
winch in two direction, even if the winch drum only round a few degree of angle,
ensure the winch is well-balanced, especially after you operated the clutch,
test-running winch can make winch in gear.
•
•
•
•
•
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 to save energy.
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 switch 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 of the vehicle for added protection.
6

n. Clear the area. Make sure all spectators are 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.
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. Rewind the 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.
WINCH ASSEMBLY AND MOUNTING
1. Your 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
popular vehicles and mounting channels. If you will utilize the mounting
channel you must ensure that it is mounted on a flat surface so that the three
7

major sections (motor, drum and gear housing) are properly aligned. Proper
alignment of the winch will allow even distribution of the full rated load.
If your winch choices the mounting channel. Start by connecting the roller
fairlead (Part# X1750900) to the mounting channel using 2 each of the cap
screw M12 X 30 (Part# X1750022), lock washer (Part# X1750021) and
securing (Make sure the screw 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.)
Assemble the winch to the mounting channel or vehicle bump base by first
pulling and releasing the clutch knob to the “CLUTCH OUT” 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 M12 x 35 cap screws (Part# X1750020) and lock
washer (Part# X1750021) secure the winch to the mounting channel.
Connect the winch motor leads as detailed below:
2.
3.
4.
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 therotating
drum. 8

7. Check for proper drum rotation. Pull and turn the clutch knob to the “CLUTCH
OUT” position. Pull out some cable from the drum, and then turn the clutch
knob to the “CLUTCH 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 accurate. If the drum is turning and collecting more
cable then reverse the leads on the motor. Repeat and check rotation.
MOUNTING DRAWING
S4000EN
O
UT
IN
WINCH ACCESSORIES YOU WILL NEED
NOT INCLUDED WITH YOUR WINCH
Gloves –For handling the wire rope and hook strap.
Anchor Strap/Chain –Tree saver anchor straps are made of high quality nylon with
high tensile strengths up to 15000lbs.
Heavy Blanket –place on the cable to absorb energy should the wire rope break.
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
9
Fig 3.1

CAUTION 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 70% rated line pull, 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 up
to 50% depending on the included angle
WARNING - Never use your winch for overhead hoisting or
for lifting people or moving people.
WINCH WORKING DEMONSTRATION
1. Disengage the clutch by turning the clutch to the “CLUTCH OUT” position.
2. Grab the cable assembly (Part# X1751100) and pull the cable to the desired length,
then attach to item being pulled.
Caution: Always leave at least five turns of cable on the drum; Review winch
safety warnings and precautions on page 2、3 before continuing.
3.
Reengage the clutch by turn the clutch assembly (Part# X1750700) to the
“CLUTCH IN” position, if the clutch is not engaged, the winch drum must be turned
by hand, until the clutch is totally engaged.
Insert the switch assembly (Part# X1751000) connector onto the control box.
Test-run winch in two directions, each direction for one or two seconds.
10
4.
5.
Fig 3.5
Fig 3.4
Fig 3.3
Fig 3.2

6. While standing aside of the tow path, hold and operate the switch assembly
supplied by your choice. To reverse directions, wait until the motor stops before
reversing directions.
7. When the pulling is complete, remove the switch assembly (Part# X1751000).
From the female connector of the directional valve and replace the female
connectors cover.
REPLACING THE WIRE ROPE
If the wire rope has become worn or is beginning to show signs of strands breaking, it
must be replaced before being used again.
1.
Turning clutch to the “CLUTCH OUT” position.
2.
Extend cable assembly to its full length. Note how the existing cable is connected
to the drum.
3.
Remove old cable assembly and attach new one as the old cable connected to the
drum. Insert the end of the new rope and secure the screw M8x10(Part#X1750008).
4.
Ensure that the new cable wraps in the same rotation direction as the old one.
The cable should leave the drum from the bottom, under the drum.
5.
Turning clutch to the “CLUTCH IN” position.
6.
Retract Cable Assembly onto drum, first five wraps being careful not to allow
kinking, then winch cable must be wound onto the drum under a load of at least
10% rated line pull.
WARNING - Only replace the wire rope with the identical replacement part
recommended by the manufacturer.
MAINTENANCE
1.
Periodically check the tightness of mounting bolts and electrical connections.
Remove all dirt or corrosion and always keep clean.
Do not attempt to disassemble the gear box.
The gearbox has been lubricated using a high temperature lithium grease
and is sealed at the factory. No internal lubrication is required.
2.
3.
11

TROUBLE SHOOTING
WARNING -
Adjustment braking angle method: The
spring according to the
spring gyrotropic pre-tight two weeks, then shows the spline tooth set according to
following braking cutaway view the adjustment angle for 20°±5°.
12
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.
Winch braking
malfunction.
-Winch working in
wrong direction.
-Brake slice worn or
worn not.
-Change winch working direction looking is to
clockwise look at the motor end
- Simply readjusted the braking angle or
replaces the new brake slice.

WINCH ASSEMBLY DRAWING
S4000EN
13

WINCH PARTS LIST
S4000EN
14
No.
Part #
Qty
Description
Remark
1
N1750001
3
Terminal Protector
2
N1750002
4
Screw M8 x 20
3
N1750003
4
Lock Washer Φ8
4
N1750100
1
Motor Assembly
5
N1750004
6
Screw M10 x 35
6
N1750005
6
Lock Washer Φ10
7
N1750006
1
Motor Bracket
8
N1750007
2
Bushing-Drum
9
N1750200
1
Break/shift Assembly
10
N1750300
1
Drum Assembly
11
N1750008
1
Screw M8 × 10
12
N1750009
3
Tie Bar
13
N1750010
10
Screw M8 x 70
14
N1750011
10
Lock Washer Φ8
15
N1750003
1
End Bearing
16
N1750012
2
Gasket
17
N1750013
1
Gear — Ring （ Output ）
18
N1750400
1
Gear Carrier Assembly （ Output ）
19
N1750014
1
Circlip For Hole
20
N1750500
1
Gear Carrier Assembly （ Intermediate ）
21
N1750015
1
Gear — Ring （ Intermediate ）
22
N1750600
1
Gear Carrier Assembly （ Input ）
23
N1750016
1
Gear — Input Sun
24
N1750017
1
Shaft Sleeve
25
N1750018
1
Trust Washer
26
N1750700
1
Clutch Assembly
27
N1750019
1
Gear — Housing
28
N1750020
8
Screw M12 × 35
29
N1750021
8
Lock Washer Ø12
30
N1750022
2
Screw M12 × 30
31
N1750021
2
Lock Washer Ø12
32
N1750900
1
Roller Fairlead
33
N1751000
1
Remote Control Switch （ RC3 ）
34
N1751100
1
Cable Assembly
35
N1750023
1
Strap
36
N1750024
1
Mounting Play
37
N1750025
1
Connecting Piece
38
N1750026
1
Connecting Piece
39
N1751200
1
Relay With Screw Assembly
40
N1751300
1
Cover With Screw Assembly
41
N1750027
1
Connecting Piece
42
N1750028
4
Connecting Block
43
N1750029
2
Connecting Rod Sets
44
N1751400
1
Battery Switch
45
N1751500
1
Emergency Stop Switch
46
N1751600
1
Hand Controller With Emergency Stop

SPECIFICATION
Pull, Speed, Amperes, Volts (First layer):
Line pull and rope capacity in layer
15
Layer
Rated line pull lbs (kgs)
Total rope on the drum ft (m)
1
8818 （ 4000 ）
18.0 （ 6.0 ）
2
7215 （ 3232 ）
40.7 （ 13.0 ）
3
5979 （ 2712 ）
65.9 （ 21.0 ）
4
5148 （ 2335 ）
85.3 （ 26.0 ）
Line Pull
Line Speed ft/min (m/min)
Current A
Ibs (kgs)
12V DC
24V DC
12V DC
24V DC
0
14.4 （ 4.4 ）
13.1 （ 4.0 ）
80
70
2205 （ 1000 ）
8.5 （ 2.6 ）
9.1 （ 2.8 ）
130
78
4409 （ 2000 ）
6.9 （ 2.1 ）
7.2 （ 2.2 ）
180
108
8818 （ 4000 ）
4.9 （ 1.5 ）
5.5 （ 1.7 ）
280
155
Rated line pull
4500KGS
Motor: series wound
12V:Input: 4.9kW/7.0hp;Output:2.9kW/3.9hp
24V:Input: 6.0kW/7.9hp;Output:3.1kW/4.1hp
Gear reduction ratio
430:1
Cable (Dia. × L)
Ø10mm × 26m
Drum size (Dia. × L)
Ø90mm × 219mm
Mounting bolt pattern
10" × 4.5"(254mm × 114.3mm) /10" × 6.5"(254mm × 165.1mm) 8-M12
Overall dimensions
(L × W × H)
610mm × 216mm × 254mm
Net weight
Ibs(kg)
60KG

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 to comply with these instructions or any improper use of the
equipment will terminate the warranty.
Please ensure you record the information below:
In the unlikely event you experience problems, contact the distributor with this
information.
16
Distributor
Date of Purchase
Invoice No
Serial No