Sherpa 4x4 Stallion Manual de usuario
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SHERPA 4x4 WINCH OWNER'S MANUAL
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PLEASE READ
WARNING!
Your winch has a duty cycle and cannot be run continuously without
allowing time to cool down. The higher the load, the higher the current
and heat produced. Remember to monitor the temperature of the winch
motors and cabling. As a rule of thumb, when winching at high loads, do
not winch for longer than 30 seconds, then follow by a 10 minute cool
down period. This will also allow your battery to rest. Overheating your
winch motor will reduce its pulling power and may lead to premature
failure.
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NOTE – Your winch performance reduces with drum layers
WinchModel
25,000lb 17,000lb 12,000lb 10,000lb 9,500lb
PullingCapacitybyLayer Rating Capacity Rating Capacity Rating Capacity Rating Capacity Rating Capacity
(lb) (m) (lb) (m) (lb) (m) (lb) (m) (lb) (m)
1st 25,000 4.3 17,000 4.3 12,500 4.3 10,000 4.4 9,500 6.2
2nd 19,000 10.1 12,730 11.5 9,520 11.5 7,580 11.4 8,260 14.2
3rd 15,320 17.4 10,570 19 7,890 19 6,310 19.8 7,040 23.5
4th 12,840 26 9,040 29 6,740 28 5,400 28 6,130 28
5th 11,040 30 8,230 45
Plan your recovery to get the most out of your winch
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OPERATION WARNINGS
WARNING! Please read and abide by the Operation Warnings to ensure personal safety
and the safety of others. Improper operation may lead to personal injury and equipment
damage. Read the following carefully before you attempt to operate your winch and please
retain for future reference.
- Uneven spooling of cable/rope while pulling a load can cause problems. If this happens,
reverse the winch to relieve the load and move your anchor point further to the centre of the
vehicle. After the recovery is complete, you can un-spool the cable/rope and rewind for a
neat layer of cable.
- Store the winch hand controller inside your vehicle where it will not be damaged or wet.
Inspect it before use.
- Always connect the controller with the clutch disengaged. DO NOT engage the clutch with
the motor running or under load.
- Avoid sudden direction changes of the winch rotation whilst winching. Allow the winch to
come to a stop before changing from ‘winch out’ to ‘winch in’ and vice versa.
- Never loop the hook back onto the cable or rope. This will cause kinking or fraying. Always
use a sling, tree trunk protector or chain of suitable strength and rating.
- Observe your winch at all times when performing a winch recovery and stand at a safe
distance. Stop the recovery every few meters to assure the cable/rope is not piling up on one
end of the winch. Jamming the cable/rope can damage your winch and cable.
- DO NOT attach tow or recovery hooks to winch mounting apparatus. They must be
attached to your vehicle frame.
- When performing a recovery with a snatch block, always maintain a direct line pull to the
centre of the winch. Ensure the hook is attached to the chassis of the vehicle.
- Ensure rated “D” or Bow shackles are used in conjunction with an approved tree trunk
protector to provide a safe anchor point.
- When extending the winch cable, ensure that at least five (5) wraps of cable/rope remain
on the drum at all times. Failure to do this could result in the cable/rope parting from the
drum under load. Serious personal injury or property damage may result.
WARNING! If replacing steel wire rope with any kind of synthetic rope, make sure the rope
can withstand the maximum capacity of your winch.
- Cable winches are provided with a red marking to identify that five (5) cable wraps remain
on the winch drum. No recovery should be attempted beyond this marking.
- Winch dampeners should always be used while winching.
- Apply blocks behind the wheels when winching vehicles on an incline.
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Battery:
Be sure that the battery is in good condition.
Always wear eye protection when working around a battery.
Ensure the engine is running when using the winch to avoid flattening the battery.
Winch Cable:
Be sure that the cable is in good condition and is attached to the winch properly.
DO NOT use the winch if the cable is frayed.
DO NOT move the vehicle to pull a load.
DO NOT replace the cable with a cable of lower strength.
The life of the 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
(230kgs) otherwise 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,
nonrecovery situation. Spool out the cable until the red cable mark appears (around five
wraps on the drum), and then rewind the cable onto the drum under a load of 500lbs
(230kgs). Winching your vehicle up a slight incline is a good way to achieve this. This will
slightly tension and stretch the cable and create a tight cable wrap around the drum. Failure
to do so may result in cable damage and reduction in cable life.
DO NOT attempt to exceed the pulling limits of this winch.
DO NOT drive your vehicle to assist the winch in any way. Vehicle movement in
combination with winch operation may overload the cable/rope or winch by causing
damaging shock loads.
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.
These winches are for recovery use in vehicle, boat and nonindustrial applications.
NEVER use the winch in hoisting applications.
DO NOT use the winch to lift, support or transport personnel.
DO NOT attempt to move the winch by lifting the clutch handle.
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WINCH INSTALLATION
Mounting Your Winch
The winch is to be mounted into a suitable steel mounting frame using the 4 point foot
mounting system in either a horizontal or vertical plane. Your winch should only ever be
installed with the rope/cable winding onto the drum on the lower side, closest to the
mounting bolts. Your winch is not designed or rated for the rope/cable winding onto the top
of the drum near the cross member supports.
Ensure your winch rope or cable is wrapping onto the drum as per the arrow stickers on your
winch. Typically, when looking at the vehicle front on, the winch motor will be installed on the
left hand side of the vehicle. Installing your winch backwards will result in the winch brake
failing to work.
It is very important that the winch is mounted on a flat surface so that the three sections
(motor, cable drum and gear housing) are properly aligned. Before commencing installation,
ensure the mounting facility being used is capable of withstanding the winches maximum
rated capacity. The fitment of winches and / or a frontal protection systems may affect the
triggering of SRS air bags. Check that the mounting system has been tested and approved
for winch fitment in air bag equipped vehicles.
The winch should be secured to the mounting plate with the steel bolts and spring washers
provided. The fairlead or hawse is to be mounted so as to guide the rope/cable onto the
drum evenly.
Your winch tie rod bolts may be loose from transport. These bolts should only be removed
one at a time so your winch holds together. Apply a drop of thread locker to each bolt and
tighten.
Winches are mounted in a high vibration environment. It is highly recommended both liquid
thread locker and spring washers are used on all connections. All connections should be
checked for tightness after 1,000km of travel.
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SPECIAL MOUNTING NOTES FOR 25,000 lb Winches
The Stallion 25,000lb winch can achieve forces which test the limits of the mounting bolts
and winch foot construction. Care must be taken when mounting this winch to reduce the
opportunity for a mounting related failure. The winch is capable of winching itself to
catastrophic destruction if the below recommendations aren’t followed.
The winch achieves it maximum recovery rating (25,000lb) when the first wrap is winding
onto the drum. If you are planning on loading the winch to this limit, it is strongly suggested
the winch be mounted such that the winch foot and bolts be in compression when winching
with the mounting bolts in the horizontal plane.
Mounting your winch with the bolts in the horizontal plane with the bolt heads facing the
vehicle in front of you is the strongest mounting arrangement as it takes much of the
winching force off the mounting bolts and winch foot mounts. The rope/cable should enter
the drum on the lower side of the drum in keeping with the direction labels on the winch.
Ensure your mount is rated for the force that can be applied.
Mounting your winch with the bolts in the vertical plane and the bolt heads pointing to the
road is acceptable, however, note, you will be operating near the limits of the bolts and the
winch foot casting when fully loading the winch. Any unbalance in forces could exceed the
design limits of the winch mount and bolts. To limit the potential for a bolt shear failure, note
the following;
Think of the mounting plate as a knife wanting to cut through the bolts. A thicker plate
is better and for the 25,000lb winch a minimum 6mm (1/4”) plate should be used.
Using a thicker 8mm (5/16”) or 10mm (3/8”) plate significantly increases the shear
strength of the mounting bolts. Using a thicker plate only at the mounting holes
achieves the same improvement and may be a lower weight option if the mounting
plate is being fabricated especially for the winch. Never mount the winch to oversized
or slotted holes as this will increase the likelihood of a bolt shear failure.
See over
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Correct torque tightening of your bolts becomes important when working at extreme
loads. Check your bolt head and match the recommended torque setting.
Bolt Grade Torque (Nm)
8.8 44
10.9 62
12.9 75
If you are planning on loading the winch to it’s limit, it is recommended that the load
be centred onto the drum to evenly distribute the force over all 4 mounting bolts
which are under a high shear stress. Uneven loading has potential to over stress the
mounting bolts when in shear.
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Mount the Solenoid Box
NOTE: The Solenoid Box can be attached to the winch, or the vehicle in various ways
depending on your vehicle type, configuration and winch mounting point. A range of brackets
are offered to assist with mounting.
Keep in mind the outer enclosure of your control box is not waterproof and is only designed
to keep the bulk of the water and dirt off the internals. The internal solenoid is IP68 rated and
suitable for submersion in water.
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Lubrication
All moving parts in the winch are lubricated with high temperature lithium grease at the time
of assembly. Under normal conditions, factory lubrication will suffice for many years of
service. If your winch is exposed to water crossings and extreme service, maintenance
inspections and frequency should be adjusted.
Lubricate the steel cable periodically using light penetrating oil. Inspect for broken strands
and replace the cable as necessary.
A small amount of lubricating oil can be applied to the engagement lever if stiffness or
engagement difficulties occur.
Cable Replacement
Unwind the new cable by rolling it along the ground, to prevent kinking. Remove old cable
and observe the manner in which it is attached to the cable drum flange. Spool the new
cable with a load of approximately 240kg. Winching the vehicle up a slight incline is a good
way to achieve tension while spooling your winch, remember to monitor winch motor and
cables temperatures when performing extended winching operations.
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