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.
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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.
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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.
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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.
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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.
•
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•
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.
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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
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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