Westin T-MAX EW-8500 User manual

FITTING INSTRUCTIONS
RECOVERY ELECTRIC WINCH
5.5 HP Series Wound Motor
Featuring the New Wireless Multi-control
New High-end Integrated Solenoid Module (ISM)

GENERAL SAFETY PRECAUTIONS
Warning! Observe safety precautions for personal safety and the safety of
others. Improper equipment operation may cause personal injury and
equipment damage.
Read the following carefully before attempting to operate your winch and
keep the instructions for future reference.
1.Dress Properly:
- Don't wear loose clothing or jewelry. They can be caught in moving parts.
- Wear leather gloves when handling winch cable. Do not handle cable with
bare hands as broken wires can cause injuries.
- Non-skid footwear is recommended.
- Protective hair covering to contain long hair.
2.Keep a Safe Distance:
- Ensure that all persons stand well clear of winch cable and load during
winch operation, 1.5 times the cable length recommended. If a cable pulls
loose or breaks under load it can lash back and cause serious personal
injury or death.
- Don't step over the cable.
- All visitors and onlookers should be kept away from the work area.
- Keep proper footing and balance at all times.
3.Don't Abuse the Cord:
- Never carry your winch by the cord or yank it to disconnect it from the
receptacle.
- Keep cord from heat, oil and sharp edges.
4.Don't Overwork the winch:
- If the motor becomes uncomfortably hot to touch, stop and let it cool for a
few minutes.
- Don't maintain power to the winch if the motor stalls.
- Don't exceed maximum line pull ratings shown in tables. Shock loads
must not exceed these ratings.
5.Avoid Unintentional Starting:
- Winch clutch should be disengaged when not in use and fully engaged
when in use.
6.Check Damaged Parts:
- Before using, you should check your winch carefully. Any part that is
damaged should be properly repaired or replaced by an authorized service
centre.
- 1 -

7.Repair Your Winch:
- When repairing, use only identical replacement parts or it may cause
considerable danger for the user.
8.Respool the Cable:
- Leather gloves must be worn while respooling. To respool correctly, it is
necessary to keep a slight load on the cable. Hold the cable with one hand
and the remote control switch with the other. Start as far back and in the
centre as you can. Walk up keeping load on the cable as the winch is
powered in.
- Do not allow the cable to slop through your hand and do not approach the
winch too closely.
- Turn off the winch and repeat the procedure until all the cable except 1m
is in.
- Disconnect the remote control switch and finish spooling in cable by
rotating the drum by hand with clutch disengaged.
- On hidden winches, spool in cable under power but keep hands clear.
Warning: The use of any other accessory or attachment other than those
recommended in the instruction manual may present a risk of personal injury.
WINCH OPERATION WARNINGS
Read the following carefully before attempting to operate your winch and
keep the instructions for future reference.
1. The uneven spooling of cable, while pulling a load, is not a problem,
unless there is a cable pile up on one end of the drum. If this happens
reverse the winch to relieve the load and move your anchor point further to
the centre of the vehicle. After the job is done you can unspool and rewind
for neat layers of the cable.
2. Store the remote control switch inside your vehicle where it will not
become damaged, inspect it before you plug it in.
3. When ready to begin spooling in, plug in remote control switch with clutch
disengaged, do not engage clutch with motor running.
4. Never connect the hook back to the cable. This causes cable damage.
Always use a sling or chain of suitable strength.
5. Observe your winch while winching, if possible while standing at a safe
distance. Stop the winching process every metre or so to assure the cable
is not piling up in one corner. Jamming the cable can break your winch.
- 2 -

6. Do not attach tow hooks to winch mounting apparatus. They must be
attached to vehicle frame.
7. The use of a snatch block will aid recovery operations by providing a
doubling of the winch capacity and a halving of the winching speed, and the
means to maintain a direct line pull to the centre of the rollers. When double
loading during stationary winching, the winch hook should be attached to the
chassis of the vehicle.
8. Ensure rated"D"or bow shackles are used in conjunction with an approved
tree trunk protector to provide a safe anchor point.
9. When extending winch cable, ensure that at least five wraps of cable
remained on drum at all times. Failure to do this could result in the cable
parting from the drum under load. Serious personal injury or property
damage may result.
10. All winches are provided with a Red Cable marking to identify that 5
cable wraps remain on the Winch drum when this mark appears at the rollers.
No recovery should be attempted beyond this marking.
11. Since the greatest pulling power is achieved on the innermost layer of
your winch, it is desireable to pull off as much line as you can for heavy pulls
(you must leave at least 5 wraps minimum on the drum-red cable). If this is
not practical use a snatch block and double line arrangement.
12. Draping a heavy blanket or similar object over the extended winch cable
is recommended as it will dampen any back lash should a failure occur.
13. Neat, tight spooling avoids cable binding, which is caused when a load is
applied and the cable is pinched between the others. If this happens,
alternatively power the winch in and out. Do not attempt to work a bound
cable under load free by hand.
14. Apply blocks to wheels when vehicles are on an incline.
15. Battery:
- Be sure that the battery is in good condition. Avoid contact with battery
acid or other contaminants.
- Always wear eye protection when working around a battery.
-Have the engine running when using the winch, to avoid flattening the
battery.
- 3 -

16. Winch cable:
- Be sure the cable is in good condition and attached properly.
- Do not use the winch if cable is frayed.
- Do not move the vehicle to pull a load.
- Do not replace the cable with a cable of less strength.
- The life of cable is directly related to the use and care it receives.
Following its first and subsequent uses, a cable must be wound on to the
drum under a load of at least 500lbs (230kg) or the outer wraps will draw into
the inner wraps and severely damage the cable during winching. The first
winch use should be a familiarisation run while in a relaxed, non-recovery
situation. Spool out the cable until the red cable mark appears (about five
wraps on the drum), then rewind the cable onto the drum under a load of
500lbs (230kg) or more. This will slightly tension and stretch the new cable
and create a tight cable wrap around the drum. Failure to do so may result in
cable damage and reduced cable life.
- When the cable is replacing, be sure to apply Loctite, or an equal
compund, to the cable clamp thread. Tighten the clamp screw properly but
do not overtighten. The locktite will prevent loosening of the screw in
arduous conditions, Loctite 7471 Primer and 222 Theadlocker are
recommended.
17. Do not attempt to exceed the pulling limits of your winch.
18. DO NOT drive your vehicle to assist the winch in any way. Vehicle
movement in combination with winch operation may overload the cable, the
winch itself or cause damaging shock loads.
19. Shock loads when winching are dangerous! A shock load occurs when
an increased force is suddenly applied to the cable. A vehicle rolling back on
a slack cable may induce a damaging shock load.
20. The winches shown in this manual are solely for vehicle and boat
mounted, non-industrial applications.
21. Never move your winch by lifting the clutch handle, which will cause
damage to clutch or injury to persons.
22. Do not use winch in hoisting applications due to required hoist safety
factors and features.
23. Do not use the winch to lift, support or otherwise transport personnel.
- 4 -

INSTALLATION
MOUNT YOUR WINCH
1. The winch is to be mounted into a suitable steel mounting frame using 4
point foot mounting system in either a horizontal or vertical direction.
2. It's very important that the winch be mounted on a flat surface so that the
three sections (motor, cable drum and gear housing) are properly asigned.
3. Before commencing installation ensure the mounting facility being used is
capable of withstanding the winches rated capacity.
4. The fitment of winches and / or a frontal protection system may affect the
triggering of SRS air bags. Check that the mounting system has been tested
and approved for winch fitment in the airbag equipped vehicle.
5. Should you wish to manufacture your own mounting plate the dimensions
below will assist. A steel mount plate 6mm thick is recommended. Fasteners
should be steel high tensile grade 5 or better. A poorly designed mount may
cause great changer and void warranty.
6. The winch should be secured to the mounting with 3/8"UNCx1-1/4"
stainless steel bolts and spring washers provided.
7. The roller fairlead is to be mounted so as to guide the rope onto the drum
evenly.
The following are winch overall dimensions and mounting patlerns for
reference before the installation.
- 5 -
163MM
6.4
205MM
8.1
114.3MM
4.5
63.5MM
2.5
254.0MM
10.0
557MM
22
254MM
10.0
254.0MM
10.0
114.3MM
4.5
EW-8500 EW-9500 EW-11000 & EW-12500
541.0MM
21.3
225.0MM
8.86
63.5MM
2.5
254.0MM
10.0
161.0MM
6.3

MOUNT INTEGRATED CONTROL BOX
There are 4 holes left on the Plate (P/N: 7329103.1-2 see the following
Integrated Control Box Part List), Which can be connected with suitable bolts
directly to a place on the vehicle you prefer; Or you may use a suitable frame to
mount this Control Box on the winch Tie Bars. Mounting Pattern is as below.
The manufacturer offers one frame for Integrated Control Box with each winch
but cannot ensure this frame be suitable for all conditions.
WARNING! The temperature of the Control Box will increase because of big
current during your winching operation. Especially during extreme winch
operation, the temperature may rise to a very high extent. Be sure not to mount
the Control Box to any place where is not heat-resist and cannot radiate heat.
Do not touch the Control Box by bare hands immediately after your winching
operation. The high temperature will hurt your hands.
LUBRICATION INSTALLATION
All moving parts in the winch are permanently lubricated with high
temperature lithium grease at the time of assembly. Under normal conditions
factory lubrication will surfice. Lubricate cable periodically using light
penetrating oil. Inspect for broken strands and replace if necessary. If the
cable becomes worn or damaged it must be replaced.
CABLE INSTALLATION
Unwind the new cable by rolling it along the ground, to prevent kinking.
Remove old cable and obsevre the manner in which it is attached to the
cable drum flange.
4X 4.5
142.5
107
- 6 -

ELECTRICAL CONNECTION
Be sure to observe the following steps for a correct and safe electrical
connection:
Step 1. Short Red cable with red sleeve(B') connecting to the red terminal (B)of
winch motor.
Step 2. Short black cable with yellow jacket(C') connecting to the yellow
terminal (C) of winch motor.
Step 3. Short black cable with black jacket(D') connecting to the black
terminal(D) of winch motor.
Step 4. Thin black cable (a') connecting to battom Terminal (A) of winch motor.
Step 5. One end of the Long Black Cable (1.8m)to Terminal (A) of winch motor
and the other end to the Negative (-)of the battery.
Step 6. Long red cable (1.8m) connecting to the Positive (+) of battery.
Warning: Never apply your winch to AC power.
- 7 -
Battery
-+
Terminal D (black)
Terminal B (red)
Terminal C (yellow)
Terminal A

WINCH OPERATION
SUGGESTION:
The best way to get acquainted with how your winch operates is to make a
few test runs before you actually need to use it. Plan your test in advance.
Remember you can hear your winch as well as you can see it operate. Get
to recognize the sound of a light steady pull, a heavy pull, and sounds
caused by load jerking or shifting. Soon you will gain confidence in operating
your winch and its use will become second nature to you.
OPERATING:
1. Ensure the vehicle is secured by applying the parking brake or chocking
the wheels
2. Pull out the winch cable the desired length and connect to an anchor point.
The winch clutch allows rapid uncoiling of the cable for hooking onto the load
or anchor point. The shifter tab located on the gear housing of the winch
operates the clutch as follows:
a) To disengage the clutch, move the clutch shifter tab to the "OUT"position.
Cable may be free spooled off the drum. b) To engage the clutch, move the
clutch shifter tab into the "IN"position. The winch is now ready for pulling.
3. Recheck all cable rigging before proceeding.
4. T-MAX Outback Series winch presents an extreme wireless multi-control.
1). Radio control: Put the plug into the
Socket. Use the handheld controller
and press button "IN" or "OUT" for wire
rope in or out. The radio control
system is exclusive to each winch.
One same handheld controller cannot
control another winch wirelessly.
2). Wire control:
Step1 Connect one end of the control cable to the interface of the handheld
pendant ;
Step2 Another end to the interface of the plug, then put the plug into the
socket, press button "IN"or "OUT" for wire rope in or out.
WARNING: Strictly obey the above steps for wire control and to avoid
unintentionally working the radio control, which will cause serious dangers.
Radio Control Specifications:
Working Voltage 9V -- 12V
Frequency 433MHz
Power 10mW
Working Temperature -20¡æ -- + 60¡æ
Maximum Control Distance 30m
- 8 -
SOCKET CONTROL CABLE
PLUG
HANDHELD
CONTROLLER

Precautions:
1) Within a distance of 200 meters, do not operate the winches with same
frequency at the same time by Radio Control, for interference will happen
among the radio signals with same frequency.
2) In case that water enters into the Handheld Controller, get out of the
battery inside and clean the circuit board with ethyl alcohol (density
required ¡Ý98%).
3) After a certain period use, change a new battery into the Handheld
Controller to ensure sufficient power to the radio control. Low voltage will
result in shorter control distance
5. To commence winching operation, start vehicle engine, select neutral in
transmission, maintain engine speed at idle.
WARNING: Never leave the plug connected to the socket when winch is not
in use. The unintentional starting of the winch will cause serious dangers.
MAINTENANCE
It is highly recommended that the winch be used regularly (once a month).
Simply power the cable out 15m, free spool 5m and then power back in. This
will keep all components in good working condition so that the winch can be
relied on when needed. Contact the authorized outlet for technical
assistance and repairs.
SPARE PARTS:
A comprehensive range of spare parts is available. For further information
please contact the Distributor on the end cover.
WINCHING CAPACITY
Pulling capacity is reduced as the incline increases. Recommended safe
loads for various inclines are listed in the table below:
Note:
1. Never winch with your vehicle in gear or in park, which would damage
your vehicle's transmission.
2. Never wrap the cable around the object and hook onto the cable itself. this
can cause damage to the object being pulled, and kink or fray the cable.
3. Keep hands ,clothing, hair and jewellery clear of the drum area and cable
when winching.
4. Never use the winch if the cable is frayed, kinked or damaged.
5. Never allow anyone to stand near the cable, or in line with the cable
behind the winch while it is under power. if the cable should slip or brake, it
can suddenly whip back towards the winch, causing a hazzard for anyone in
the area. Always stand well to the side while winding.
6. Don't leave the switch plugged in when winch is not in use.
- 9 -

Note:
1. This guide is recommended for average vehicle rolling loads. Some
applications may require a larger winch than indicated.
2. The weight the winch could pull perpendicular to the ground with a single
line on the first layer of cable on the drum.
3. A 10% grade is a rise of one metre in ten metre.
4. Winch is not intended as a load securing device.
NOTE:
The safety precautions and instructions discussed in this manual can't cover
all possible conditions and situations that may occur. It must be understood
by the operator that common sense and caution are factors, which cannot be
built into this product, but must be applied by the operator.
10%
7538
10050
12563
17588
30151
47690
47739
55219
60240
62749
Rated Line Pull
1500lb
2000lb
2500lb
3500lb
6000lb
9500lb
10000lb
11000lb
12000lb
12500lb
20%
5102
6803
8503
11905
20408
32300
32313
37399
40800
42499
40%
3233
6347
5388
7543
12931
20425
20474
23648
25800
26874
60%
2496
2816
4060
5824
9983
15770
15833
18259
19920
20737
80%
2134
2407
3556
4979
8535
13490
13515
15619
17040
17393
100%
1928
2175
3213
4499
7712
12160
12211
14079
15360
15990
- 10 -

FEATURES & SPECIFICATIONS
EW-8500 (12V /24V) FEATURES& SPECIFICATIONS
EW-8500 (12V /24V) LINE SPEED & AMP DRAW - FIRST LAYER
EW-8500 (12V /24V) LINE PULL AND CABLE CAPACITY
- 11 -
Layer of cable 1 2 3 4
Rated line Lbs 8500 7432 6730 6245
Pull per layer Kgs 3852 3370 3050 2830
Cumulative Ft 16 42 72 94
Cable capacity m 5 12 21 28
Lbs NO 2000 4000 6000 8000 8500
Line Pull
Kgs LOAD 906 1813 2719 3626 3852
12v 37.20 18 13.76 10.71 8.61 7.56
ft/min
24v 46 22 18 .9 15.12 11.03 9.98
Line Speed
12v 11.34 5.49 4.19 3.26 2.62 2.30
M/min
24v 14.02 6.71 5.76 4.61 3.36 3.04
12v 70 190 250 315 395 405
Motor Current amps
24v 45 90 135 157 192 205
Rated Line Pull 8500LB (3852kg) Single-line
Motor 5.5hp 12v Series Wound;6hp 24VSeries Wound
Control Wireless Multi-control
Gear train 3-Stage Planetary
Gear reduction ratio 172.8:1
Clutch Sliding Ring Gear
Braking Automatic In-The-Drum
Drum size Diameter 2.52" (64mm)Length 8.82"(224mm)
Cable 94' 21/64" diameter(28.5m,8.2mm diameter)
Fairlead 4-way roller fairlead
Remote Control Included
Recommended Battery 650CCA minimum for winching
2
Battery Leads 25mm , 72"(1.83m)
Finish Dark Gray
Weight 80.5lbs(36.5kg)
Overall dimensions (LxWxH)22"x6.3"x8.1"(557x160x205mm)
Mounting Bolt Pattern 10.00+0.015INx4.50+0.010IN(254x114.3mm)
--

EW-9500 (12V /24V) FEATURES & SPECIFICATIONS
EW-9500 (12V /24V) LINE SPEED & AMP DRAW - FIRST LAYER
EW-9500 (12V /24V) LINE PULL AND CABLE CAPACITY
- 12 -
Rated Line Pull 9500LB (4300kg) Single-line
Motor 5.5hp 12v Series Wound;6hp24V Series Wound
Control Wireless Multi-control
Gear train 3-Stage Planetary
Gear reduction ratio 218:1
Clutch Sliding Ring Gear
Braking Automatic In-The-Drum
Drum size Diameter 2.52" (64mm)Length 8.82"(224mm)
Cable 94' 21/64" diameter(28.5m,8.2mm diameter)
Fairlead 4-way roller fairlead
Remote Control Included
Recommended Battery 650CCA minimum for winching
2
Battery Leads 25mm , 72"(1.83m)
Finish Dark Gray
Weight 84lbs(38kg)
Overall dimensions (LxWxH)21.15"x6.3"x8.6"(537x160x218mm)
Mounting Bolt Pattern 10.00+0.015INx4.50+0.010IN(254x114.3mm)
--
Lbs NO 2000 4000 6000 8000 9500
Line Pull
Kgs LOAD 906 1813 2719 3626 4305
12v 29.5 14.4 12.1 10.1 9 7.5
ft/min
24v 41.7 20.5 15.4 14 12.1 10.2
Line Speed
12v 8.99 4.39 3.69 3.08 2.74 2.29
M/min
24v 12.71 6.25 4.69 4.27 3.69 3.11
12v 70 170 235 300 365 405
Motor Current amps
24v 50 90 120 140 175 200
Layer of cable 1 2 3 4
Rated line Lbs 9500 8435 7640 7086
Pull per layer Kgs 4305 3822 3460 3212
Cumulative Ft 16 42 72 94
Cable capacity m 5 12 21 28

- 13 -
EW-11000 (12V /24V) FEATURES & SPECIFICATIONS
EW-11000 (12V /24V) LINE SPEED & AMP DRAW - FIRST LAYER
EW-11000 (12V /24V) LINE PULL AND CABLE CAPACITY
Rated Line Pull 11000LB (4985kg) Single-line
Motor 5.5hp 12v Series Wound;6hp 24VSeries Wound
Control Wireless Multi-control
Gear train 3-Stage Planetary
Gear reduction ratio 265:1
Clutch Sliding Ring Gear
Braking Automatic In-The-Drum
Drum size Diameter 2.52" (64mm)Length 8.82"(224mm)
Cable 94' 23/64" diameter(28.5m,9.2mm diameter)
Fairlead 4-way roller fairlead
Remote Control Included
Recommended Battery 650CCA minimum for winching
2
Battery Leads 25mm , 72"(1.83m)
Finish Dark Gray
Weight 95lbs(43kg)
Overall dimensions (LxWxH)21.3"x6.3"x8.6"(541x160x218mm)
Mounting Bolt Pattern 10.00+0.015INx4.50+0.010IN(254x114.3mm)
--
Lbs NO 2000 4000 6000 8000 10000 11000
Line Pull
Kgs LOAD 906 1813 2719 3626 4532 4985
12v 26.20 13.80 12.45 10 7.40 6.80 6.50
ft/min
24v 32.58 17.30 14.30 11 9.80 8.70 8.30
Line Speed 12v 7.99 4.21 3.80 3.05 2.26 2.07 1.98
M/min
24v 9.93 5.27 4.36 3.35 2.99 2.65 2.53
12v 70 145 207 270 330 375 400
Motor Current amps
24v 45 85 115 140 165 190 205
Layer of cable 1 2 3 4
Rated line Lbs 11000 9500 8490 7800
Pull per layer Kgs 4985 4305 3850 3535
Cumulative Ft 16 42 72 94
Cable capacity m 5 12 21 28

- 14 -
EW-12500 (12V /24V) FEATURES & SPECIFICATIONS
EW-12500 (12V /24V) LINE SPEED & AMP DRAW - FIRST LAYER
EW-12500 (12V /24V) LINE PULL AND CABLE CAPACITY
Rated Line Pull 12500LB (5665kg) Single-line
Motor 5.5hp 12v Series Wound;6hp24VSeries Wound
Control Wireless Multi-control
Gear train 3-Stage Planetary
Gear reduction ratio 265:1
Clutch Sliding Ring Gear
Braking Automatic In-The-Drum
Drum size Diameter 2.52"(64mm) Length 8.82"(224mm)
Cable 94' 3/8" diameter(28.5m,9.5mm diameter)
Fairlead 4-way roller fairlead
Remote Control Included
Recommended Battery 650CCA minimum for winching
2
Battery Leads 25mm , 72"(1.83m)
Finish Dark Gray
Weight 95lbs(43kg)
Overall dimensions (LxWxH)21.3"x6.3"x8.6"(541x160x218mm)
Mounting Bolt Pattern 10.00+0.015INx4.50+0.010IN(254x114.3mm)
--
Lbs NO 2000 4000 6000 8000 10000 12000 12500
Line Pull
Kgs LOAD 906 1813 2719 3626 4532 5438 5665
12v 23.50 12.60 10.30 8.90 7.50 6.50 5.25 4.50
Ft/min
24v 26.40 15.10 13.25 11.20 10 8.60 7.50 7.10
Line Speed
12v 7.16 3.84 3.14 2.71 2.29 1.98 1.60 1.37
M/min
24v 8.05 4.60 4.04 3.41 3.05 2.62 2.29 2.16
12v 70 125 165 215 270 330 390 405
Motor Current amps
24v 45 85 105 135 155 185 210 215
Layer of cable 1 2 3 4
Rated line Lbs 12500 10700 9575 8800
Pull per layer Kgs 5665 4850 4340 3790
Cumulative Ft 16 42 72 94
Cable capacity m 5 12 21 28

WINCH EXPLODED VIEW
EW-8500 WINCH EXPLODEDVIEW
- 15 -

EW-9500 WINCH EXPLODED VIEW
- 16 -

EW-11000 WINCH EXPLODEDVIEW
- 17 -

EW-12500 WINCH EXPLODED VIEW
- 18 -