Electric Winch Warrior 135PHS12 / 135PHA12 User Manual

Quick Guide from the Manual

This manual provides essential instructions for the safe operation and maintenance of the Warrior 135PHS12 and 135PHA12 electric winches. Key safety requirements include:

• Intermittent Use Only: Allow the winch to cool down between uses. Do not use for constant duty applications.
• No Lifting People: Never use the winch to lift or move people. Do not use as an overhead hoist.
• Cable Safety: Maintain a minimum of five wraps of cable around the drum barrel for pulling and holding the rated load. Never step over a cable under load.
• Load Management: For loads over 70% of rated line pull, use a snatch block to double the line and reduce load on the winch.

Getting to Know Your Winch

The winch consists of several key components:

• Motor: Powered by a 12V or 24V battery.
• Winch Drum: The cylinder where the wire rope is stored.
• Free Spooling Clutch: Allows manual disengagement of the drum for free spooling.
• Roller Fairlead: Guides the wire rope onto the drum and minimizes abrasion.
• Remote Switch: Allows operation from a safe distance.

Assembly and Mounting

The winch is designed with a standard bolt pattern. Ensure the mounting surface is flat to allow proper alignment of the motor, drum, and gear housing.

1. Connect the roller fairlead to the mounting channel using the provided M10 cap screws, flat washers, lock washers, and locknuts.
2. Assemble the winch to the mounting channel by pulling the clutch knob to the "CLUTCH OUT" position, feeding the wire rope through the fairlead, and securing the winch with the remaining hardware.
3. Connect the battery and motor leads according to the wiring diagram.
4. Assemble the clevis hook to the cable.
5. Check for proper drum rotation by engaging the clutch and testing the "cable out" function. If the drum collects cable instead of releasing it, reverse the motor leads.

Operating Instructions

Follow these steps for safe winching:

• Preparation: Put on gloves, disengage the clutch, and pull out the required length of cable using the hand saver hook.
• Rigging: Secure the clevis hook to an anchor point using a sling, chain, or snatch block. Never attach the hook back onto the wire rope.
• Operation: Engage the clutch, connect the remote, and start the vehicle engine to maintain battery power. Stand clear of the cable and operate the switch.
• Completion: Once the vehicle is on stable ground, secure it, release tension on the wire rope, and disconnect the remote.

Replacing the Wire Rope

If the rope is worn or damaged, it must be replaced:

1. Set the clutch to "CLUTCH OUT" and extend the cable to its full length.
2. Remove the old cable assembly and attach the new one, securing it with the M8x10 screw.
3. Ensure the new cable wraps in the same rotation direction as the old one (leaving the drum from the bottom).
4. Retract the cable, ensuring the first five wraps are tight and free of kinks.

Maintenance

• Periodically check the tightness of mounting bolts and electrical connections.
• Keep the winch clean and free of dirt or corrosion.
• Do not attempt to disassemble the gearbox; it is sealed at the factory and lubricated with high-temperature lithium grease.

Troubleshooting

If the winch fails to operate, check the following:

• Motor does not turn: Check switch assembly connection, battery cable connections, or potential water ingress.
• Drum does not turn: Ensure the clutch is fully engaged.
• Motor runs slowly: Check for insufficient current or voltage; operate with the vehicle engine running.
• Motor overheating: Allow the winch to cool down periodically.