ZEAK 2500LB User manual

ZEAK 2500LB
WINCH

WARNING: Read carefully and understand all ASSEMBLY AND
OPERATION INSTRUCTIONS before operating. Failure to follow
the safety rules and other basic safety precautions may result in
serious personal injury.
Keep this manual and the receipt in a safe and dry place for future reference.
ZEAK 2500LB
Electric ATV WINCH
12 Volt

WARNING:
CAUTION:
Electric Winch Use and Care
2 SPECIFIC OPERATION WARNING
3 INTRODUCTION
Technical Specifications
5 OPERATION INSTRUCTIONS
CATALOGO
1 SAFETY
Important Safety Information 1
Work Area Safety 1
Personal Safety 2
2
General Safety 3
3
3
Installation Safety
5
Winching Safety
Mounting the Solenoid Assembly 7
Circuit Break Protection Rubber Sleeve 9
Clutch Operation 10
Operation Warning 11
6 TROUBLESHOOTING 14
7 MAINTENANCE 15
8 PARTS DIAGRAM 16
9 REPLACEMENT PART 17
Duty Cycle 13
Wiring 8
4 ASSEMBLY INSTRUCTIONS
Mounting the Winch 7
Hazardous Chemicals Warning 1

Important Safety Information
Hazardous Chemicals Warning
This product may contain chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm. Wash hands after handling.
Work Area Safety
Inspect the work area before each use. Keep work area clean, dry, free of clutter,
and well-lit. Cluttered, wet, or dark work areas can result in injury. Using the
electric winch in confined work areas may put you dangerously close to other
cutting tools and rotating parts.
Keep children and bystanders away from the work area while operating the tool.
Do not allow children to handle the electric winch.
1.SAFETY
Read and understand all instructions. Failure to follow all instructions may result
in fire, serious injury and /or DEATH.
The warnings, cautions, and instructions in this manual cannot cover all possible
conditions or situations that could occur. Exercise common sense and caution
when using this electric winch. Always be aware of the environment and ensure
that the electric winch is used in a safe and responsible manner.
Do not modify this electric winch in any way. Unauthorized modification may
impair the function and/or safety and could affect the life of the electric winch.
There are specific applications for which the electric winch was designed.
Do not allow persons to operate or assemble the electric winch until they have
read this manual and have developed a thorough understanding of how it works.
Use the right tool for the job. DO NOT attempt to force small equipment to do the
work of larger industrial equipment. There are certain applications for which this
electric winch was designed. The tool will be a safer and do the job better at the
capacity for which it was intended. DO NOT use this equipment for a purpose for
which it was not intended.
Industrial or commercial applications must follow OSHA requirements.
11
WARNING

Personal Safety
Electric Winch Use and Care
Stay alert, watch what you are doing, and use common sense when operating
the electric winch. Do not use the electric winch while you are tired or under the
influence of drugs, alcohol, or medication. A moment of inattention while operat-
ing the tool may result in serious personal injury.
Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep
your hair, clothing and gloves away from moving parts. Loose clothes, jewelry, or
long hair can be caught in moving parts. Air vents on the tool often cover moving
parts and should be avoided.
Wear the proper personal protective equipment when necessary. Use ANSI Z87.1
compliant safety goggles (not safety glasses) with side shields, or when needed,
a face shield. Use a dust mask in dusty work conditions. Also use non-skid safety
shoes, hardhat, gloves, dust collection systems, and hearing protection when
appropriate. This applies to all persons in the work area.
Inspect before every use, do not use if damaged or parts loose. Examine the
winch for structural cracks, bends, damage, frayed or kinked wire rope, and any
other conditions that may affect the safe operate of the winch. Do not use the
winch even if minor damage appears. A kink permanently weakens the wire rope,
even after it is straightened out; kinked wire rope can fail suddenly and must not
be used.
Do not overreach. Keep proper footing and balance at all times.
Do not force the electric winch. Products are safer and do a better job when used
in the manner for which they are designed. Plan your work, and use the correct
electric
Store the electric winch when it is not in use. Store it in a dry, secure place out of
the reach of children. Inspect the electric winch for good working condition prior
to storage and before re-use.
Use only accessories that are recommended by the manufacturer for use with
your electric winch. Accessories that may be suitable for one product may create
a risk of injury when used with another tool. Never use an accessory that has a
lower operating speed or operating pressure than the tool itself.
2
CAUTION

2.SPECIFIC OPERATION WARNING
General Safety
1.To prevent injury or property damage, read and understand all instructions
before operating winch.
2.Wear ANSI Z87.1 compliant safety goggles and heavy duty leather work
gloves during operation.
3.Do not exceed the rated load capacity. Be aware of dynamic loading! Sudden
load movement may briefly create excess load causing product failure.
Installation Safety
1.Choose a mounting location that can support the winch and rated load
capacity.
2.Do not weld mounting bolts.
3.Use supplied power cords and wire rope listed in manual only. Do not use
thinner/longer cablesor link multiple cables together.
4.Keep hands clear of winch rope, hook loop, hook and fairlead opening during
installation, operation, and when spooling in or out.
5.Wrap the wire rope under 500 lbs. of tension before use. Otherwise, the wire
rope may bind during operation.
6.Do not route electrical cables near sharp edges or parts that will move or
become hot.
7.Ventilate area well before and while working on battery. Explosive hydrogen
gas can accumulate and explode when ignited by a spark or open flame.
8.Only connect to a clean, corrosion free battery.
9.Remove all jewelry and metallic objects before working near battery.
Winching Safety
1.Inspect winch rope, hook, and slings before operating winch. Frayed, kinked
or damaged winch rope must be replaced immediately. Damaged components
must be replaced before operation.
2.Do not maintain power to the winch if the motor stalls. Verify the load is
within the rated capacity for the wire rope layer. Make sure the battery is fully
charged. Use double line rigging whenever possible.
3.Do not engage or disengage clutch while under load.
4.Always ensure hook latch is closed and not supporting load.
5.Never apply load to hook tip or latch. Apply load only to the center of hook.
6.Never use a hook whose throat opening has increased, or whose top is bent
or twisted.
7.Keep clear of fairlead when operating. Do not try to guide wire rope.
8.Do not place any fingers through the hook. Fingers may be caught and get
pulled into the fairlead or drum. Use the included strap to hold the hook instead.
3

9.Stay out of the direct line that the wire rope is pulling. If it slips or breaks, it
will create a whiplash effect. Utilize a winch dampener to help absorb the force
released if the wire rope breaks.
10.Do not use for overhead hoisting. This winch is intended to be used for
pulling only.
11.Use a spotter to assist you in ensuring that it is safe to operate the winch.
Make sure the spotter is out of the way of the vehicle and the wire rope before
activating the winch.
13.Do not use vehicle to pull on the wire rope and “assist” the winch.
14.Do not use to transport people or animals.
15.Disconnect battery cables before working near the wire rope, drum, fairlead
or load, to prevent accidental starting.
16.Keep wire rope straight to avoid kinking the wire rope.
17.Keep children and bystanders away while operating.
18.Hook onto the object using a pulling point, tow strap or chain. Do not wrap
the wire rope around the object and hook onto the wire rope itself.
19.Do not use a recovery strap while winching.
20.Secure the load after moving. Do not lock the mechanism.
21.Keep at least 5 full turns of wire rope on the drum.
22.Keep clear of the wire rope, hook, and load while winching. Do not step over
the wire rope. Do not push sideways against the wire rope under tension; wire
rope might break under this load and recoil back, striking the person pushing
against it or a bystander.
23.If the wire rope begins to get entangled, stop the winch immediately and
release the wire rope using the switch.
24.Only winch with the winching vehicle’s transmission placed in neutral.
Winching with a vehicle’s transmission in gear or park may damage the transmis-
sion. A vehicle’s transmission is not designed to handle this type of load.
25.Do not operate the winch on extreme slopes. Do not exceed the angles for a
roller fairlead. For a hawse fairlead, the angle should be as close to 180 degrees
as possible.
26.People with pacemakers should consult their physicians before use. Elec-
tromagnetic fields in close proximity to heart pacemaker could cause pacemaker
interference or pacemaker failure.
27.Remove any element or obstacle that may interfere with safe operation of
the winch.
28.Always use supplied hook strap whenever spooling winch rope in or out,
during installation and during operation.
29.Always take time to use appropriate rigging techniques for winch pull.
12.Do not use the hand crank, if equipped, to assist the winch.
4

3.INTRODUCATION
The ZEAK 2 500-Lb. 12 Volt DC Electric ATV Winch has plenty of power to assist
in ATV recovery traversing rough terrain or loading a boat. This winch is a reli-
able and safe addition to any off-road adventure.
Technical Specifications
5
Layer Wire Rope CapacityRated Line Pull
First layer of Wire Rope Performance
2
1
3
4
5
6
2500lb (1134kg) 6’ (1.8m)
2045lb (928kg) 13.3’ (4.0m)
1731lb (785kg) 21.9’ (6.7m)
1500lb (680kg) 31.8’ (9.7m)
1324lb (600kg) 43.1’ (13.1m)
1184lb (537kg) 50’ (15.2m)
Line Pull (lb.) Amp Draw (@12v)Line Speed fpm(mpm)
1
0 13.3(4.1) 10
1000 8.3(2.5) 55
2000 4.1(1.2) 106
2500 2.7(0.8) 132

6
Winch Specifications
Rated Single Line Pull 2 ,500 lb.
Motor
Horsepower (hp.) 1.1
Switching Method Mini Rocher
12V DC
Permanent Magnet
Gear Train Gear Ratio 153:1
Freespool Pull and Trun KnobBrake System Dynamic
Single-Stage Planetary
Drum Size(in.) 1.25’’ X 2.8’’
Hook 1/4” Clevis with Latch
Fairlead Hawse Fairlead
Battery
Minimum 12Ah
12V DC Battery Cables 10 Gauge, 5.8’ long
Solenoid Cables 10 Gauge, 1.3’ longSolenoid Solenoid
Weather-sealed
Mounting Bolt Pattern 3.15”(80mm)
3x G8
Winch:
M8- 1.25X35mm
2x G8
Fairlead:
M8-1.25 X19mm
Warranty one year
Mounting Hardware
Rope Material Synthetic
Rope Length(ft.) 50 Rope Diameter(in.) 3/16
Sound Rating 85dB
Dimensions 11.7” x3.97” x4.13” Weight 13.55 lb
IP Rating IP 65
Duty Cycle Rating 5% (45 Sec at Max Rated Load; 14 min, 15 Sec Rest)
Item
Qty
Description
C
B
F
DE
4.13in.
5.2in.
C
A
3.94in.
2.83in.
11.7in.
3.15in.
EF
G
G
B
D
A
0.33in./8.5mm4-

4.ASSEMBLY INSTRUCTIONS
Mounting the Winch
1.The mounting plate must be rated to at least the winch’s capacity.
2.Align the winch perpendicular to the center line of the center line of the vehi-
cle at the desired location and mark the locations of the winch base holes. Com-
pare the dimensions of the marked holes.
3.Before drilling, verify that the installation surface has no hidden components
or structural pieces that will be damaged.
(Note: This winch can generate extreme forces. Select a location that can with-
stand the rated capacity without damage or weakening. Steel reinforcement
plates may be needed or a certified welder may need to weld on additional brac-
ing depending on the mounting location.)
4.Drill holes appropriate for the hardware at the marked locations.
5.Install the winch using hardware described under Specifications.
Mounting the Solenoid Assembly
1.Mount the solenoid box in proper location so that:
a. The winch components are close enough to each other to allow wires to
be routed properly.
b. The vehicle component operations is not interfered with.
c. The vehicle components are not damaged by drilling or driving screws.
d. The winch components will not damaged by stresses caused by vehicle
operation.
2.Mark the location where the screw holes will be.
3.Verify that the installation surface has no hidden components or structural
pieces that will be damaged before drilling.
4.Drill pilot holes for the mounting screws.
5.Secure in place with mounting screws.
7

Wiring
To prevent serious injury from explosion (sparking at the battery connection),
disconnect the battery cables before making other wiring connections.
To prevent serious injury from leaking battery acid, do not use a dirty, corroded
or leaking battery. Only use a 12V automotive (or equivalent) battery, in good
condition.
1.Plan a route for the wiring from the point of the vehicle where the winch will
be mounted, or used, to the battery. This route must be secure and out of the way
of moving parts, road debris, or any possibility of being damage by operation or
maintenance of the vehicle.
For example, you may wish to route the wires under the vehicle, attaching it
to the frame using suitable fasteners Do not attach the wires to the exhaust
system, drive shaft, emergency brake cable, fuel line, or any other components
which may create damage to the wiring through heat or motion, or create a fire
hazard.
2.If you drill through the bumper or any part of the body to route the wires, be
sure to install a rubber grommet in the hole to prevent fraying of the wires at that
point.
3.Route the cables from the solenoid to the battery and from the solenoid to
the winch, following the precautions discussed above. See the following picture.
4.Attach the wires from the solenoid to the terminals on the winch.
5.Attach the circuit breaker to the positive terminal on the battery.
6.Attach the red battery cable to the circuit breaker.
Wiring Connection
(Note: The attachment of the motor cables determines the operation of the
remote’s button. After the unit is mounted and powered, check the direction of
the Power In and Power Out on the remote button. If you wish to change the
direction on the remote, disconnect the battery cables from battery, switch the
motor cable connections on the motor, then reconnect the battery cables.)
8

Preparing the Wire
1.The wire rope must be properly coiled under tension to be able to support a
load without damage.
2.Uncoil the wire rope, expect for 5 full wraps.
3.Recoil the rope back into the winch under at least 500lb. of tension.
Circuit Break Protection
Rubber Sleeve
9
How to Use It
You only need to heat it evenly with a hot air blower or a candle to make it shrink
they can be used for circuit break protection,
group of lines marking, resistance electric
capacity reason protection

5.OPERATION INSTRUCTIONS
1.Inspect the winch rope, hook, and slings before operating the winch. Frayed,
kinked, or damaged winch ropes must be replaced immediately. Damaged com-
ponents must be replaced before operation.
2.Wrap the wire rope under 500 lbs. of tension before use. Otherwise, the wire
rope may bind during operation.
3.Ventilate the area well before and while working on the battery. Explosive
hydrogen gas can accumulate and explode when ignited by a spark or open
flame.
4. Remove all jewelry and metallic objects before working near battery.
Warning:
1.Read the entire Important Safety Information section at the beginning of this
winch.
2.The instructions that follow are basic guidelines only and cannot cover all
situations encountered during use. The operator and assistants must carefully
plan usage to prevent accidents.
Clutch Operation
1.The position of the pin in the shaft determines whether the clutch is engaged
or not.
2. How to change clutch position
a) Pull clutch knob out.
b) Turn it 90° while it is pulled out, then
release it.
10
Shaft
Pin
Drum
End
Shaft
Pin
Drum
End
If the pin rests
in the groove in the drum
the clutch is engaged.
If the pin rests
on top of the end of the
drum the clutch is released.

OPERATION WARNING
Note: If a winch is to be used to pull a vehicle, it should optimally be rated to a
single line pull at least twice the vehicle’s weight.
Leave at least five full turns of wire rope on the drum.
1.Examine the wire rope. Do not use the winch if the wire rope is frayed,
kinked, or damaged.
2.Fully charge the vehicle’s battery.
3.Check the winch’s electrical connections. All connections must be tight and
clean.
4.Put the vehicle’s transmission in ‘Neutral’.
5.If the vehicle (where the winch is mounted) is not supposed to be moved,
engage the emergency brake and block the wheels using wheel chocks (sold
separately).
6.Hook onto the object using a pulling point, tow strap, tree strap, or chain. See
the following picture.
8.Do not use a recovery strap while winching. They are designed to stretch and
can suddenly whip back towards the operator during a winching operation.
9.Place a heavy rag or carpet (sold separately) over the wire rope span 6 feet
from the hook to help absorb the force released, if the wire rope breaks.
7.The attachment point must be centered in loop of the hook and the hook’s
safety clasp must be fully closed. See the following picture.
11
Do not wrap the wire rope around the object and hook onto the wire rope itself.
This can damage the object being pulled, and kink or fray the wire rope.

10.To pull out the wire rope, move the clutch control to the release position
(shown in the following picture), slide the loop of the hook strap over the hook,
then pull on the hook strap to pull out the wire rope.
11. Move the clutch control to the engaged position.
12.Operation the controls briefly to ensure they work properly.
The retract button should power out the cable.
The extend button should power cables.
If operation is reversed, the power cables may be connected backwards.
Correct any such issue before use.
13. When it is safe to do so, use the power switch on the pendant controller to
retract the wire rope, and winch the item as desired. Do not power the hook all
the way into the fairlead to prevent damage.
14. Do not operate the winch at extreme angles. Do not exceed the angles shown
below for a roller fairlead. For a hawse fairlead, the angle should be as close to
straight as possible.
15.If the object to be pulled must be pulled at an angle in relation to the winch,
use a pulley (sold separately) and an anchor point directly in front of the winch
(see illustration) to keep the wire rope pulled straight.
12
Do not allow anyone to stand near the wire rope, or in-line with the wire rope
behind the winch while it is under power. If the wire rope should slip or break,
it can suddenly whip back towards the winch, causing a hazard for anyone in
the area. Stand to the side while winching.
Stop the winch and release tension on the wire rope before moving the rag or
carpet placed on it

16.Do not continue use of the winch until the battery is completely run down.
Stop before it reaches that point.
17.When possible, keep the engine running while using this winch to continu-
ally recharge the battery and prevent the battery from being drained so much that
the vehicle cannot start. However, you should see extreme caution when working
around a running vehicle and ONLY operate a vehicle in an outdoor area.
18.When finished pulling the load, reverse the direction of the winch just
enough to release tension on the wire rope so that you can unfasten the hook
from the load and reel in the wire rope.
19.Disconnect the pendant controller (if equipped) after use.
Duty Cycle
Avoid damage to the winch by not winching for more than the prescribed duty
cycle time.
The duty cycle defines the amount of time, within a 15 minutes period, during
which a winch can operate at its maximum capacity without overheating. For
example, this winch with a 5% duty cycle at its maximum load must be allowed to
rest for at least 14 minutes, 15 seconds after every 45 seconds of continuous
operation. Failure to carefully observe duty cycle limitations can easily
over-stress a winch contribution to premature winch failur
Wipe external surfaces of the winch with a clean cloth.
13
45 seconds winching
at least
14 minutes,
15 seconds
of rest

6.TROUBLESHOOTING
Use the table below to troubleshoot problems before contacting service
personal or your local dealer. If the probem continues after troubleshooting,
call your local dealer for istance.
Follow all safety precautions whenever diagnosing or servicing the tool
Disconnect power supply before service.
14
Failure Possible Cause Corrective Action
Motor overheats 1.Incorrect power cords
2.Winch is running too long
1.Use only supplied power cords
2.Allow winch to cool down periodically
Motor does
not turn on
1.Remote battery is dead
2.Loose battery cable connec-
tions
3.Vehicle battery needs charging
4.Solenoid is malfunctioning
5.Remote damaged
6.Defective motor
7.water has entered motor
8.Internal damage or wear
1.Replace remote battery
2.Tighten nuts on all cable connections
3.Fully charge battery
4.Tap solenoid to loosen
contacts. Apply 12 volts to coil
terminals directly. A clicking
indicates proper activation
5.Replace remote
6.Check for voltage at armature port with
switch pressed. If voltage is
present, replace motor
7.Allow to drain and dry. Run in
short bursts without load until
completely dry
8.Have technician service winch
Motor runs but
wire rope
drum does not
run
Clutch not engaged
Move the clutch handle to the
engaged position. If problem persists,
a qualified technician needs to check
and repair
Motor runs
slowly or
without normal
power
1.Insufficient current or
voltage
2.Loose or corroded battery
cable connections
3.Incorrect power cords
1.Battery weak, recharge it. Run
winch with vehicle motor running
2.Clean, tighten, or replace
3.Use only supplied power cords
Motor runs in
one direction only
1.Defective or stuck solenoid
2.Remote damaged
1.Tap solenoid to loosen contacts Repair
or replace solenoid
2.Replace remote

7.MAINTENANCE
1.To prevent serious injury from accidental operation: disconnect the battery
cables before operate any inspection, maintenance, or cleaning.
2.Performing any inspection, maintenance, or cleaning procedures.
3.To prevent serious injury from winch failure: do not use damaged equipment. If
an abnormal noise or vibration occurs, have the problem corrected before further
use.
4.Lubricate the wire rope occasionally corrected before further use.
5.The winch’s internal mechanism is a permanently lubricated. Do not open the
housing. However, if the winch is submerged, it should be opened, dried, and re-lu-
bricated by a qualified technician as soon as possible to prevent corrosion.
15

8.PARTS DIAGRAM
16
Base Plate Assembly
Tension Plate
Hex Flange Nut M5
Screw M5 X 10MM
Hex Socket FH SCREW M6 X 16MM
Bushing
Synthetic Assembly
Drum Assembly
Screw M5X8MM
Pin 2.5 x 2
Clutch Assembly
Spring
Spine
Drum Support Bushing
Pan Head Screw M4X 12MM
Drum Support Plate
Rotator Gear
Gear Ring
Planetary Gear Assembly
Motor
Winch Mounting Hardware
Hawse Fairlead
Fairlead Mounting Hardware
Hook
Red Strap
Pendant Controller
Control Box
Circuit Breaker
Parts List
Part Number Description Quantity
Clutch Knob 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
4
1
2
2
2
1
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
21
23
24
25
26
27
28
29
20
22
2
3
24
25

REPLACEMENT PART
Not all product components are available for replacement. The illustrations
provide are a convenient reference to the location and position of parts in the
assembly sequence.
When ordering parts, the following information will be required: item descrip-
tion, item model number, item serial number/item lot date code, and the replace-
ment part number.
17