Westin T-MAX ATW4500 User manual

FITTING INSTRUCTIONS
NEW
ATW4500
M73080930A

VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
INTRODUCTION
Thanks for your interesting in T-MAX Products, especially the ATW4500, and we sincerely hope that it will
satisfy you. We not only have the professional capability to design winches but also with comprehensive
after-sale service. Please do not hesitate to contact us for any further messages or suggestions.
Please do tell us the following information when you need to replace any parts of winch:
1. The series no. of winch, for instance 88808290001 which is shown no the top of the winch base.
2. The item no. of winch spare parts which is listed on the table of winch spare parts.
3. The exactly description of winch spare parts.
GENERAL SAFETY PRECAUTIONS
Please read and understand this owner’s manual before installing and using your new winch. Pay particular attention
to the General Information. Your winch is a very powerful machine. If used unsafely or improperly, there is a possibility
that property damage or personal injury could result. We have included several features in this winch to minimize this
possibility. However, your safety ultimately depends on your caution when using this product.
As the operator of this product the responsibility for safe operation ultimately lies with you. It is imperative that you read
and understand all of the safety precaution instructions prior to installing and operation your winch. Failure to understand
the proper operation of this product can result in serious injury and/or property damage.
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. The notation is also
used to alert you to unsafe practices.
Note:
1. The above symbols in the Owner’s manual are used to indicate additional information in the installation and operation
procedures.
2. ATW4500 is designed primarily for intermittent duty general use. This winch is not designed to be used in industrial or
hoisting applications. ATW4500 does not warrant it to be suitable for such use. T-MAX manufactures a separate line of
winches for industrial/commercial use. Please contact us for further information.
UNPACKING
This carton contains the following items. Please unpack carefully.
DANGER
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DANGER
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WARNING
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VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
Packaging list of ATW4500
Parts List of ATW4500
2
Description Qty
ATW4500, W/ WIRE ROPE or W/SYNTHETIC ROPE 1
REMOTE CONTROL 1
ROLLER FAIRLEAD or ALUMINUM FAIRLEAD 1
MOUNTING HARDWARE KIT 1
OWNER’S MANUAL 1
MOUNTING PLATE 1
WIRE CABLE (1.8Mx10MM) 2

VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
EXPLODED VIEW OF ATW4500
Item Part No. Description Qty
1 GB/T70 M6×120 Bolt M6 X 120 2
2 7241100.1.3-2 Motor End Cover 1
3 7241100.1.1.3.1 Carbon Assy 1
4 7241100.1.1 Stator 1
5 7241100.1.2 Rotor 1
6 GB/T-85 M6×18 Bolt M6X18 4
7 7241100.1-1 Motor Frame Cover 1
8 7241100.3-1 Drum Base 2
9 7241100.8 Torque Limiter 1
10 GB/T276-1994 Bearing 2
11 7241100.2 Drum 1
12 7241100.0-1 Tie Rod 2
13 7241100.3-9 Sun Gear 1
14 7241100.0-3 Spring 1
15 7241100.8-7 Washer 1
16 7241100.3-3 Inner Gear- Output 1
17 7241100.5 Braking System 1
18 7241100.3.1-4 Gear Spindle 3
19 7241100.3.1-1 Gear Carrier 2
20 GB/T276-1994 61812 Bearing 2
21 7241100.3.1-3 Planetary Gear 3
22 7241100.3-4 Anti-friction Gasket 1
23 7241100.3-5 Inner Gear 1
24 7241100.3-8 Clutch Yoke 1
25 7241100.3-7 Inner Lock washer 1
26 7241100.3-2 Gear Box Tube 1
27 GB/T3452.1 23.6×1.80 O Ring 1
28 7241100.3-6 Clutch Cover 1
29 7241100.0-2 Mounting Plate 1
30 GB/T5782-2000 M8×20 Bolt M8 X20 2
31 7241100.4 Roller Fairlead 1
32 7241100.7 Wire Rope 1
33 RU104206 Clevis Hook 1
34 7309200.7-2 Aluminum Fairlead 1
35 9163151 Synthetic Rope 1
36 7241100.6-1 Short Black Cable (10mm2 x 5cm) (wrapped by Black
Thermoplastics Pipes) 1
37 7241100.6-2 Short Black Cable (10mm2 x 10cm) (wrapped by Red
Thermoplastics Pipes) 1
38 7241100.6-3 Short Black Cable (10mm2 x 12cm) (wrapped by Yellow
Thermoplastics Pipes) 1
39 7241100.6.2 (W) Control for ATV Use (match to Wire Rope) 1
7241100.6.2 (S) Control for ATV Use (match to Synthetic Rope) 1
40 7241100.6.4 Socket Assy 1
41 7241100.6-4 Long Cable (10mm2 x 180cm) 1
42
7241100.6.3 (W) Remote Handle Control for UTV & Utility Use (match to Wire
Rope) 1
7241100.6.3 (S) Remote Handle Control for UTV & Utility Use (match to
Synthetic Rope) 1
43 7241100.6.4 (W) Control Box Assy(match to Wire Rope) 1
7241100.6.4 (S) Control Box Assy (match to Synthetic Rope) 1
44 7241100.6.1 ISM 1
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VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
DEMENSION
Note: The unit of dimension is mm.
Features & Specications:
P/N: 7241100
Rated Line Pull: 4500 lbs (2040kgs) Single-line
Motor: 12V DC, 0.8KW (Series Wound)
Control: Remote Control
Gear Ratio: 148:1
Clutch: Turn 90°By Hand wheel
Barking: Eccentric Block Type
Drum Size: Diameter 2.0” (52mm) x Length 4.7” (119mm)
Recommended Battery:650CCA Minimum for Winching
Fairlead: Roller Fairlead
Cable: Length (15m) x Diameter (6.3mm)
Mounting Bolt Pattern: 6.7” (169mm) x 3”(76mm)
Weight: 16KGS
Overall Dimensions: (LxWxH) 14.6”x4.7”x5.1”(372mm x 120mm x129mm)
4
EXPLODED VIEW OF ATW4500’s CONTROL BOX
No. Part No. Description Qty
17329200.6A-10 Plug Cover 1
27329200.6A-11 Socket 1
37241100.6.5-1 Mini box 1
47241100.6.5-2 Radio Sender & Receiver 1
57241100.6.1 ISM 1
6GB/T93 6 Washer 8
7GB/T41 M6 Nut 8
87241100.6.5-3 Mounting Plate 1
9GB/T70.2 M5×10 Bolt 8
10 7241100.6.5-4 Control Box soleplate 1

VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
P/N: 7241110
Rated Line Pull: 4500 lbs (2040kgs) Single-line
Motor: 12V DC, 0.8KW (Series Wound)
Control: Remote Control
Gear Ratio: 148:1
Clutch: Turn 90°By Hand wheel
Barking: Eccentric Block Type
Drum Size: Diameter 2.0” (52mm) x Length 4.7” (Length)
Recommended Battery:650CCA Minimum for Winching
Fairlead: Aluminum Fairlead
Synthetic Rope: Length (18m) x Diameter (6mm)
Mounting Bolt Pattern: 76mm x 169mm
Weight: 13KGS
Overall Dimensions: (LxWxH) 14.6”x4.7”x5.1”(372mm x 120mm x129mm)
Line Pull Line Speed Motor Current
lbs (kgs) ft/min (m/min) Amps
0 39.4 (12) 40
1000 (454) 21.3 (6.5) 50
1500 (680) 14.8 (4.5) 70
2000 (907) 11.2 (3.6) 90
2500 (1134) 8.9 (2.9) 110
3000 (1360) 7.5 (2.5) 140
3500 (1587) 6.2 (2.0) 160
4000 (1814) 5.6 (1.9) 180
4500 (2040) 5 (1.7) 200
Above performance specs are based on rst layer of drum
Wire rope layer Pulling power Cable Capacity per Layer
1st is closest to drum lbs (kgs) ft(m)
1st 4500 (2040) 11(3.4)
2nd 3728 (1690) 25(7.6)
3rd 3180 (1445) 41(12.5)
4th 2775 (1260) 59(18)
INTERMITTENT DUTY
ATW4500 is like any other motor driver power tools such as an electric drill or saw. The electric motor should not be
allowed to become excessively hot. Normally precautions will extend the life of your motor. Keep the duration of pulls as
short as possible. If the end of the motor becomes uncomfortable hot to touch, stop winching and allow the motor to cool
down.
If the winch motor stalls, do not continue to apply power to the winch.
GERNERAL SAFTEY PRECAUTIONS
ATW4500 is a powerful machine. Treat it with respect, use it with caution and always follow the safety guidelines.
The wire rope or synthetic rope before the winch stalls. For heavy loads, use a pulley block to reduce
the load on the wire rope.
1. Maximum working load capacity is on the rst layer closest to the drum is around 4500lbs (2040kgs). Do not overload.
Do not attempt prolonged pulls at heavy loads. Overloads can damage the winch and/or the wire rope and create unsafe
operating conditions. For loads over 1,000 pounds we recommend the use of a pulley block to double line the wire rope.
This reduces the load on the winch and the strain on the wire rope by approximately 50%. Attach hook to load bearing
parts. The vehicle engine should be running during winch operation. If considerable winching is performed with the
engine of, the battery may become too weak to re-start the engine.
CAUTION
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WARNING
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VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
2. After reading and understanding this manual, learn to use your winch. After installing the winch practice using it.
3. Do not move your vehicle to assist the winch in pulling the load. The combination of the winch and vehicle pulling
together could overload the wire rope and winch.
4. Keep a safety distance. Ensure that all people stand well clear of winch during the operation. Always stand clear of
wire rope, hook and winch. To avoid the unlikely event of component failure, it is best that you and other are out of harms
way.
5. Inspect the wire rope and equipment frequently. A frayed wire rope with broken strands should be replaced
immediately. Always replace wire rope with T-MAX’s identical replacement part. Periodically check the winch installation
to ensure that all bolts are tight.
6. Use leather gloves when handling the wire rope. Do not let the wire rope slide through your hands even when wearing
gloves.
7. Never winch with less than 5 turns of wire rope or synthetic rope around the winch drum since the wire rope end
fastener will not withstand a load.
8. Always use the hand saver bar or hook strap (if so equipped) when guiding the wire rope in or out. (See Figure 4)
9. Keep clear of the winch, taut wire rope and hook when operating the winch. Never put your nger through the hook.
If you nger should become trapped in the hook, you could lose your nger. Never hook the wire rope back onto itself
because you could damage the wire rope. Use a nylon sling. (See Figure 1)
Figure 1
10. If a wire rope failure should occur, the cloth will act as a damper and help prevent the rope from whipping. (See
Figure 2)
Figure 2
11. Your winch is not designed or intended for overhead hoisting operations. Never use your winch for lifting or moving
people.
12. Avoid continuous pulls from extreme angles as this will cause the wire rope to pile up at one end of the drum. This
can jamb the wire rope in the winch, causing damage to the winch or the wire rope.
13. Always operate the winch with an unobstructed view of the winching operation. Equipment such as tackle, hooks,
pulley blocks, straps, etc. should be sized to the winching task and should be periodically inspected for damage that
could reduce their strength.
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VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
14. Take appropriate precautions to disable the winch when not in use or under supervision to prevent use by children or
other unauthorized persons. Do not operate the winch when under the inuence of drugs, alcohol or medication.
15. When moving a load, slowly take up the wire rope slack until it becomes taut. Stop, recheck all winching connections.
Be sure the hook is properly seated. If a nylon sling is used, check the attachment to the load.
16. When using a winch to move a load, place the vehicle transmission in neutral, set the vehicle parking brake and
chock the wheels.
17. Do not machine or weld any part of the winch. Such alterations may weaken the structural integrity of the winch.
18. Do not power the winch longer than 120 seconds. The drum and wire rope/synthetic rope may get too hot
19. Do not connect the winch to either 110C AC house current or 220V mains as winch burnout or fatal shock may occur.
Never allow shock loads to be applied to the winch or wire rope.
20. Use caution when pulling or lowering a load up and down a ramp or incline. Keep people, pets and property clear of
the path of the load.
INSTALLATION
MOUNTING YOUR WINCH
Step (1)
Choose a mounting location that is sufciently proper and safe to install your winch. The thickness of the location must
be at least 3/8” (4.8mm).
Do drill four holes which diameter is 9.5mm and position is 169mm x 76mm as Figure 3.
Note: Different banners or models of UTV/ATV maybe has respective place of mounting.
Figure 3
Step (2)
Let the mounting bolt through the holes (which is drilled in Step one) and the mounting plate from the bottom up.
Note: To use the Mounting bolts (M8 X 32MM) and washer which are supplied by T-MAX.
ATW4500 should be secured to the mounting with 3/8”UNC*1-1/4” steel bolts and spring washers provided.
NOTE:
If the mounting location is special, please use the bolt (M8 X32MM) and the washer to x ATV4500 rstly, and then x
the other two of the four spare holes diagonally in the same way.
Step (3)
a.Turn the clutch cover as 90°with the direction of “ Free spool”;
b.Let the wire rope through the roller fairlead;
WARNING
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VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
c. To connect the clevis hook on the wire rope;
d.Turn the clutch cover as 90°reversely to engaged the clutch;
NOTE:
To turn the drum, the clutch is engaged if it could be turned; or to repeat as “c” once more;
e.To x the roller fairlead on the mounting plate.
NOTE:
If the rope is synthetic rope, you can x the aluminum fairlead on the mounting plate, and then reel the rope. Please see
the method of how to do that as the attached interleaf.
Installation Drawings
ISM Control Box
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VEHICLE RECOVERY ELECTRIC WINCH FITTING INSTRUCTIONS
T-MAX
UTV SERIES
Step (4)
Note: This step is aim at who purchase the ATW4500 with Control Box.
a. Discharge two bolt of the tie rod which is which is at the side of motor, and then to x the control box and screw the
two bolt back.
b. According to the above Figure of the Electric Theory, to connect the point “B”, “C” and “D”.
Step (5)
a. Choose one place which thickness is between 2 and 5mm to install the Chrome Plated Aircraft Socket;
b. To drill there holes which specications are as “Figure of How to Install the Socket”
c. Discharge the nut on the socket, and let the wire through the biggest hole;
e. Use the M3X16 Bolt to fasten the socket
Step (6)
a) To install the Control (which is for ATV use) on the left handlebar;
b)To fasten the Control (which is for ATV use) after to readjust it on a suitable position;
NOTE:
1. The current is circulated when the vehicle works.
2. Do wrap the cable with rubberized fabric to make sure all the wires is orderly.
Figures of How to Install the Socket
Step (7) Electrical Connection
a) Long Red Cable (length: 1.8m; diameter: 10mm), one terminal to the bottom terminal of the motor, and the other
terminal connecting to positive (+) terminal of the battery the red terminal of the motor.
b) Long Black Cable (length: 1.8m; diameter: 10mm), one terminal to the bottom terminal (A) of the motor, and the other
terminal connecting to negative (-) terminal of the battery the red terminal of the motor.
NOTE:
1. Be sure battery cables are not drawn taught across any surfaces, which could possible damage them.
2. Be sure battery cables are not drawn taught across any surfaces, where is too hot or tight.
3. Clean all connections especially in remote control switch and receptacle.
9
1 and 2 is optional