Thomas Winch Owner's Manual 603k2h

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THOMAS

THOMAS EWBCOO Electric Winch Kit

WINCH INDUSTRIES (AUSTRALIA) PTY. LTD., 70 Colebard Street West, Archerfielrl. Brisbane, Oueenslancl Australia, 41 0i: Telephone (Oll 277 5166 Telex: AA 42637 Cables "WINCHE:: ' Brisbane ;:'ilblication No.

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CONGRATULATIONS

Y6u have purchased the finest winch available today.

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was designed and manufactured in Australia to give reliable service in all operating

conditions.

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By necessity, your THOMAS WINCH develops considerable povrer and care should be exercised at all times during winching operations. Often, there are easier and faster ways of getting the job done if certain precautions are taken first.

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V/e have prepared this manual to help you to get to know your THOMAS !V li! CH and its proper and efficient use. Some important safety hints have been included also. \Ye hope that this informaiion contributes in a positive way

your chosen four

to your enjoymen'.

o{

rryheel drive.

lf used in accordance with the instructions provided, your THOMAS WINCH will give you many years o{ f aithful and troubie-free service.

Thank you for selecting THOMAS

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it's reassuring to have one pu!!ing for you'

WARNING

The THOMAS WINCHES described herein have NOT been designed or approved for the transportation of personnel. Under no circumstances will WINCH INDUSTRIES (AUSTRALIA) PTY. LTD., or its agents or resellers be responsible for any injury or damage arising out of

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improper use of the winch.

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THOMAS WINCHES are sold on the express understanding that there is no implied warranty that the winch shall be fit for the purpose of lifting or moving persons or other improper use, and there is no implied warranty of merchantability

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for such purposes.

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THOMAS EWSOOO 12 OR 24 VOLT DC ELECTRIC WINCH

GENERAL INFORMATION

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The Winch Rope is able to be Free Spcoled (i.e. No Power Required) off the Drum. The Dog Clutch Handle is in the D_SSrg3ggg[ Position when standing vertical. When not using the Winch or when travelling, the handle should be in

ihe vertical or disengaged position. The engaged position is 20o oif vertical outward away from the Winch Drum. 2.

3.

CAUT|ON for Safety Reasons. lt is not possible to Disengage the Dog Clutch on the Winch Under Load. Switch off Winch by use of pendantcontrol. YouiWinch will automatically stop, wherr pressure is reieased from $Jinch Siaritch. CAUTION. Do not leave pendant control (operating suritchi plugged into Control Box receptacle when Winch is not in use, or when using the Hand Crank (where this option is instailed) on your "Thomas" Winch. CAUTION: Ensure Wlnch Motor has completely stopped before reversing the Winch.

lmoortant. (a) Your "Thomas" EW8000 Electric Winch is rated at 8000 lbs. line pull on bare drum. To ensure maximum line pull always anchor to the furtherest, not neai-est point when winching.

(b) The Grubscrew in the Winch Drum is NOT designed to withstand the Line Pull that the Winch is able to deliver. Therefore it is most important that no winching

is ever

wire rope on the drum at all times.

undertaken unless there are 8 wraps of

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TECHNIOUES !-E OPERATION

with the operation of your THoMAS winch is advisabre to famiriarise yourserf before You reallY need to use it'

lt

l-:-re best

various situations' way is to set up a few test runs in

?.anyourwinchingoperationinaclvance'Learntorecognise'bysightandsound' have had some experience your winch in all conditions' Once you '.re operation of

your winch and its use' winching operations a:d have gained some confidence in rr;ii beco;'ne second nat'ure' that your winch

wiil not only puil you up a slope, it will

also lower

vehicle or a load while your you <Jown. You can also pull (or lower) another position' is secured in a stationaiy vehicle

techniques' Try ihem yourself {oliorving illustrations show a fevr winching you have gainecl to practise in more demanding ancj trren use the knorvieclge

-i-he

s:iu ations.

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T SINGLE LINE PULL

YourTHoli4ASwinchisratedaccordingtoitsSlNGLELlNEPULL capacity on the first Iayer of cable on the drum' As the layers increase in number, the single line pull rating is progressively reduced.

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By using a SNATCHBLOCK, the load capacity of a rvinch can be increased. A single sheave snatchblock will give twice the capacity and half the load on the winch. (i.eThe time taken to winch a given cJistance is increased proportionately double Iine pull = double time).

NOTE: The cable rnust be brought right back on itseli and anchored ncar the winch to be

ef

feciive.

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WINCHING RANGE Your THOMAS winch is fitted with cable guide rollers which will allorv you to pull over a fairly wide range. Puil from an angle only to straighten up your vehicle. Continuous pulling to one side may result in damage to your vehicle or to the guide roller assemb!y.

BROKEN CABLES Always carry a set of cable clamps of a size suitable for your winch rope. Never install less than two cable clamps

(76 mm) separation'

with not

less

than 3 inches

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BURIED ANCHOR

Anyreasonablylargeandsolidobjectcanbeusedasananchorifnothingmore suitable is available'

*Buryalogsufficientlydeeptoensurethatitcannorbedislodgedduring A dirt mound along the winching side of the log will assist' winching.

Bury your spare tyre horizontallyabout half

A boat

sand anchor makes an ideal

a

metre down'

buried anchor'

nasty situatlon' A shovel held by one person can get You out of a

Useashieldtoprotecthimagainstinjuryshouldther.ebeacablebreak. Locatethetowropeasfardownthehandleaspossibleformaximumleverage.

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::'.';'ENTIONAL ',',,'ching is acccmplished using a suitable existing anchor point located line of the vehicle' .n close proximity to the extelrded centre

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EARTH ANCHOR points are not available' Very often' suitable existing anchor

Threeorfourtimberorstar-picketstakesburieduprightinlinewiththe towing direction make a workable substitute'

Attachthewinchcabletoaslingorropewhichhasbeenfirmlysecuredto ALL stakes.

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SAFETY TIPS As with all machinery, there is potential danger in winching operations, but there is very little to be afraid of if the basic dangers are recognised and reasonable care is taken. The following safety tips will help ensure that every time you need to use your winch is a successful one'

1.

ALWAYS DISENGAGE the dog clutch after completion of winching. lf a P.T.O. winch, also ensure thatthe P.T.O. unit is disengaged. Failure to do so may result in your vehicle and/or winch being heavily damaged'

2.

KEEP CLEAR of the winch cable at all times during pulling. Ensure that everyone remains at a safe distance to either side of the cable'

3.

DON'T STEP over or near a winch cable under tension unless protected by an adequate shield.

4.

USE GLOVES or a heavy rag to protect hands from burrs lvhen handling a

winch cable.

5.

DON'T GUIDE a winch cable under tension by hand'

6.

PLACE BLOCKS under wheels if vehicle is on

7.

ENSURE CLUTCH is fully engaged before use. This applies also to P.T.O.

ln I'r

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a slope.

IN

unit if P.T.O. winch'

g.

DON'T USE the winch cable loaci on the

9. 10.

winch.

as a

tow rope or move the vehicle to pull

a

Cable breakage may result.

DAMAGED CABLES should be replaced immediately. WHEN PULLING a heavy load where there is even the remotest chance of cable failure, place a tarpaulin, blanket, floor carpet or any other heavy material over the cable about 5-6 metres from the hook. This will slow any snap-back should cable failure occur and may save someone {rom serious injurY.

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Safety Tips (continued)

11.

EVEN SPOOLING of the cable is not critical to the winch's operation. Do not worry about an even lay while winching, unless you get a bunch-up at one end of the drum. You can respool after the job's done

for

a neat lay.

12. ANCHOB POINTS should be located as near as possible to the extended centre line to the front of the vehicle.

13. ALWAYS CARRY extra cable hardware, shear pin (P.T.O. cnly) and a suitable anchor for use in open areas.

14.

A Mlt'Jl|VUM of 4 tc 6 wraps of the cable around the drum is required to hold the rated load.

15.

A SNATCHBLOCK should be used to reduce the stress on the cable and winch in high load situations.

16.

VEHICLE POWER can be used to assist the winch, but do not overtake the winch cable.

17.

STAY OUT of and away from the vehicle while winching in a hazardous area.

18.

SLINGS SHOULD always be used around the anchor point. Never loop the winch rope around and onto itself as this will cause irreparable damage.

19.

ALWAYS LOCATE sling as near maximum load bearing capacity.

20.

NEVER USE a sling on a living tiee. Use asuitable fabric strap. Wire rope slings, particularly, will ringbark the tree and cause it to die.

as

possible to ground ievel as this gives

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THOMAS

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12 OR 24 VOLT DC ELECTRIC WINCH

SUGGESTED WINCHING PROCEDURE

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Go to the front of vehicle. Check that the Winch Dog Clutch is in the vertical (disengagd) position. Draw winch rope off drum anC using the shackle provided, fix the end of the rope to anchor point. (ln everv 'vinching situation make sure that the anchor you are using can withstand the loaj). Do not run your Winclr rope around the anchor point, and shackle the end cf the rope back onto itself.

You will ruin your winch rope immediately. Wrap:ither (1)Our "Thomas" Strapping Type "Tree Saver" Sling (2) "Thomas" Large Eyed Type, Double Ended Chain. 2.

Look along where your Winch Rope is laying and cr:ck that the Rope will not foul etc., when winching is carried out.

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lnsert the pendant control into the socket proviCec on the Winch Control Box.

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your switch is of the Rocker

Type.

P|essure on

the bottom of the

SwitchwillresultinaWl!operation.P.:ssureonthetopofthe

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EWSOOO

switch will result in a WINCHING OUT operation. Your "Thomas" Winch will stop when pressure is released off the switch, and ii returns automatically to thE CENTRAL Or OFF POSITION. 5.

To assist your battery, start engine if possible selec: neutral gear and keep it at fast idle while winching. To ease the load on the \Vinch and battery, your vehicle may be winched and driven at the same time. Be careful not to foul the WINCH ROPE with the vehicle.

6.

Your pendant control is designed to allow winching to be accomplished from either outside or inside your vehicle. Use the Switch intermittently, until slack is taken up. Avoid sudden jerks on the cable and slowly increase the load.

7.

For even rope winding on to the drum, the vehicle should be gently steered from side to side. Observing if possible that the rope lays as evenly as practical' Sharp crossovers must be avoided if possible, as these will damage your rope.

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Suggested Winching Procedure (continued)

8.

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The renowned "Thomas" EW8000 Electric Winch will hold all loads (up to the breaking point of either the wire rope or winch) so winching may be stopped at any time with safety. Even up or down the steepest

gradients. , however, when attempting winching operations which may possibly be dangerous ensure that yourWinch and Rope are in first class order and have been maintained correctly' 9.

To obtain a Mechanical advantage the use of a "Thomas" Snatch Block will almost double yourWinching capacity. Rigging with a Snatch Block will reduce the load on the SJinch and line by approximately one half' This will in turn allow the Motor to run faster, and reduce the Amperage Draw. Long Heavy Pulls can be accomplished in this manner'

10.

Always pull in as straight a line as possible.

11.

After winching

completed keep pressure on the re and spool evenly onto the drum. (A heavy Basil Glove is a desireable asset in this operation if the wire rope is run through the hand). Release pressure on the Switch when the shackle is approximately 1 foot off the rollers. Then use switch intermittently till the shackle and rope can be secured to the top horizontal is

Make sure rope is well tensioned on drum (and cannot shake loose when travelling over rough terrain). Remove pendant control from winch

roller.

receptacle and stow in vehicle for safe keeping'

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HAND CRANK

ln the event of Power Failure, or for various other reasons, the patented "Thomas" Hand Crank will ensure that winching can still be carried out' Repeat instructicns as previous re anchoi'ing. lnsert Hand Crank in

position provided. Ensure vehicle is in neutral gear and hand brake off' commence lvinching by rotating hand crank.

lt

is advisable

not to have

'the pendant control connected to the Winch Conirol Box'"vhile conduciing this operation.

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THOMAS ELECTRIC WINCHES TROUBLE SHOOTING GUIDE CONDITION MOTOR RUNS IN ONE DIFIECTION

POSSIBLE CAUSE (1 )

Defective solenoid or stuck solenoid.

CORRECTION (1 )

by spplying '12 volts to coil terminal (it should maks an audible click wh€n

ONLY (2) Defective switch

MOTOR FIUNS EXTR EM

E

MOTOFI FUNS, BUT WITH INSUF-

FICIENT POWEF, OR WITH LOW LINE SPEED

energized).

(2) Disengage winch clutch or rsmove armatu16 l€ad. Bemove switch plug

from hood. Raise connrctor covgr on hood and with a screw driver, short the bottom two pins. Solenoid should click. Short the two left hand pins. The other solenoid should operate. lf both solsnoids operate, check for a broken wira in switch cabla.

(3) Broken wire or bad connection

(3) Check for loose connection on switch and switch connector. Spread pins apsrt slightly if nrcessary.

(1) Armature dragging

bushings for excessive wsar. Replace if worn badly. (2) Replace if cause not d€termined.

LY

HOT

Jar solenoid to free s. Check

(2) Detective motor (3) Long period of operation (1

) lnsufficient Battery

(1 ) Chect<

(3) Allow to cool.

(3) Bad connection

terminal voltage under load. lf 10 volts or lsss, replace or parallel another battery to it. (2) Check battery to ground (chassis) cable. Must be No. 2 or larger. (3) Check battery terminals for corrosion,

(4) I nsufficient charging system

(4) Replace with larger capacity chsrging

(2) Battery to winch cable too smali

(1

) Check battery

clean and grease, system.

MOTOR FIUNS, BUT DRUM DOES NOT TU BN

MOTOR WI LL NOT OPE RATE

) Clutch not engaged (2) Sheared drum shaft key (3) Stripped bronze gear (4) Parted shaft

(1) lf clutch engaged butsymptom still

(1 )

(2) Defective switch

Jar solenoid to free s. Check bv applying 12 volts to coil terminal (it should make an sudible click when energizad). (2) Disengage winch clutch or r€move armBture lead. Bemove sw.itch plug from hood. Raise connector cover on hood and with a screw driver, short the bottom two pins. Solenoid

(3) Oefective motor

should click. Short the two left hand pins. Th€ other solenoid should operate. lf both solenoids operate, check for a broken wire in switch cable. (3) lf solenoids oper6te, check for voltage at armature post, if present, replace motor. (4) Tighten connections on bottom side of hood and on motor.

(1

Defective solenoid or stuck solsnoid

(4) Loose cmnections

exists, it will be nocessary to disassenble rryinch to determine cause and repair.

{1 )

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TROUBLE SHOOTING GUIOE (continusd)

CONDITION CLUTCH JUMPS

uNoER LOAD

POSSIBLE

OUT

CAUSE

(1) Clutch jaws have ben damaged (1) Replace clutch and drum, or the clutch and clutch ring which is or worn by partial engagement bolted to ihe drum. on previous hesvy pulls

CLUTCH BINDS

(1) Dry or rusty shaft (2) Keys pulled out of shape

CLUTCH INOPERATIVE

(1

OI

L LEAKS

F

HOUSINGS

ROM

CORRECTION

) Loose set

screw

(2) Lost key (3) Bent yoke (l

) New

(1) Clean and lubricate. (2) File oif burrs or replace keys. Tighten' (2) Fleplace. (3) Straighten or replace. (1 )

(1) New sesls sometimes l€ak until

seal

(2) Saal damag€d (3) Too much oil

or'ilorn

seated to shaft. (2) Fleplace' (3) Drain excess oil per lubrication i

(4) Damaged

gasket

nstruc

ti o ns.

(4) RePlace.

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ItTtAINTENANCE

Check periodically oil level in both ,.vorm rnd gs.lr'5ox. This c;n [:e accomplished by obsenving at orl filler plugs. GraCe of oil in Gear Box Approx. 1i3 of a

pint "Thomas" T1896

Speciai

Gear 8ox Oil. Grade of oil in Worm Box Approx. 2l3 of aoin,

"tito.ur"

T'l 666 Special

Worm Box Oil. Grease at regular intenrals through nipples prcvided.

Clean and ret;ghten all electrical ccnnecticns ct regular intelials.

No maintenance of the mechanical works of rhe \rYinch is required. lnspect Wire Rope after use for kinks er dantage.

THOMAS ACCESSORIES

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HEAVY DUTY SNATCH BLOCKS Single and multi sheave blocks in

a

variety of sizes.

CABLE HARDWARE A complete range of cable is stockei.

hardr,";are

CHAIN AND WIRE SLINGS Standard slings are available ex stock. Special slings made to order.

\ryINCHES AND TOWING ROPES Virire ropes

of any Crameter and length

for any purpose.

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,,THOMAS"

EWSOOO

12 VOLT ELECTRIC WINCH KIT

FITTING INSTRUCTIONS

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1.

Remove existing bumper

2.

-Bolt

bar and brackets from

chassis side raiis.

rails 4,,x3,,x12%" extensionanglessupplieC ontooutsiCe cf chassis side supplied washers ' using eight 1" x 318" bolts' nuts 6p6i 5pring

the

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b'''l n posi"n

:::ilJi,,1:iT,?",:::,i:ili:r:;,il;;$::::lli.T:'lhen

4.Replacebumperbarbracketsonoutsideofextensionanglesusingeight 1" x 3l8" bolts, nuts and spring washers supplied'

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5'

Refit torv hooks on top of winch frame'

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,,THbMAS"

EWSOOO

12 VOLT ELECTRIC WINCH KIT

FITTING INSTRUCTIONS

TOYOTA TRUCK AND HARDTOP

IMPORTANT

1.

Fill rrlorm box with Castroi Hypi'ess B140 oil supplied through the square oil

!evel

piug at the side of the wornr box housing. Ttris plug is situated just above the electric motor.

2. Fill electric

motor gear box with smali bottle

of oil suppiied.

This oil is inserted through lhe1,1a" Hexagon Allen screw levei plug at the front of

the gear box.

FITTING INSTRUCTIONS

1.

Remove bumper bar and

2.

Remove triangular bumper bar plates located on the top of the chassis side rails and discard.

3.

Position winch on chassis side rails and bolt in place, using the lour 1%" bolts. nuts and spring washers supplied.

4.

Bolt four 4" x2%" bumper bar extension plates supplie<J to existing bumper bar brackets using eight 1" x318" bolts, nuts and spring washers supplied.

5.

Refit bumper bar using existing bolts.

6.

Refit tow hooks on top of winch frame

tow

hooks.

if

desired'

xlk"

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,,THOMAS" EWsOOO 12 VOLT ELECTRIC WINCH KIT

FITTING INSTRUCTIONS

NISSAN PATROL, FOBD F1OO, FORD F250, LANDROVER,JEEP

1.

Remove bumper bar and fittings.

Locate winch on chassis side rails and secure with existing bolts and bolts suppl!ed.

2.

Refit bumper bar.

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,,THOMAS"

EWSOOO

12 VOLT ELECTRIC WINCH KIT

INSTALLATION OF ELECTRICAL CONTROL BOX

Once winch installatiorr is completed, control box can nor,v be mounted rn situation above electric motor in position provided.

lMlo_Er4Ir (a)

Ensure good earth between base

It is important to that rryinch frame and control box.

of conirol box

anC 'ryinch

irarie.

all the',vinch conti-ol por,ver flows tnrcuch thr

Clean the winch frame in the area under r,vhich the control box is to be i:ositionecj by f iling or sanding to bright metal.

Locate controi box and secure firmiy. Repaint exposed areas where paint has been removed to avoid rust. lnspect periodically and reclean as necessary.

(b) To enable your "THO[/AS" winch to deliver fuil rated line puli, it ensure that

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full battery power

is available

is necessary

to

to the winch motor.

Connections must be kept clean and tight'

An earth strap, connected from one of the three bolts securing the electric mctor

to the winch gear box direct to the eanh terminal of your vehicle battery,

is

recommended should earthing problems occur.

The "UQ_MAS" Earthing Strap Part No. TE640 is available required.

as an

optional extra if

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,,THOMAS"

EWSOOO

12 VOLT ELECTRIC WINCH KIT

WIRING INSTRUCTIONS _ GENERAL

(For front mounted installations where the winch motor

is

situated on the driver's side

of the vehicle.)

1.

Slip the rubber boots supplied over the black, blue and vellow cables before making connections to winch motor terminals. Ensure that

all connections to the winch motor are clean and tight.

Position rubber boots over the motor terminals after connections have been made. This will protect ihe terminals against atmospheric corrosion and u-rill maintain good earthing or electrical .

2.

Connect black cable (armature)

3.

Connect blue cable

4.

Connect yellow cable

to terminal

stamped ,,A,, on rvinch motor.

to terminal stamped "F2" on winch motcr-. to terminal stamped "Fl" on winch motor.

NOTE; F1 and F2 terminals

are side by side. Should an alteration of the running rotation of the winch be required to suit a particular winch installation,

the blue and vellow wires can be changed over on their terminals with no detrimental effect on winch or motor.

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5.

Connect red battery cable

to

positive (+) battery terminal.

This assumes electrical polarity of the vehicle is neqative to earth. i.e. the frame of the veh icle.

NOTE: Onthe

Nissan Patrol. the red battery cable is connected

to the positive

(+)

side of the vehicle starter motor.

This assumes electrical polarity of the vehicle is negative to earth, i.e. the f rame of the vehicle. .

"MUa$1EWB00o

12

voLT

ELECTRTC WTNCH KtT

WIRING INSTRUCTIONS

-

TOYOTA

(For any front mountjng installation where the winch motor

is

side of the vehicle.)

situated on the enger

1. slip the rubber

boots supplied over the black, blue and vellour cables before making connections to lvinch rnotor terminals.

Ensure that alr connections

tc the r,vinch motor are clean and tight. Posltion rubber boots o'rer the motor terminals after connections have been made. This will protect the terrninals against atmospheric corrosion and will maintain

good earthing or electr.ical .

2.

Connect black cable (arnrature) from control box to terminal stamped ,,A,,on 'ayinch

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motor.

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conriect biue cabre

4.

connect velrorv cabre to ternrinar stamped "F1,, on erectric motor.

NorE:

to

terminar stamped

"F2" on erectric motor.

F1 and F2terminals are side by side. Should an alteration of the running -tutlorrof the winch be required to suit a particular winch installation, the blue and vellow wires can be changed over on their terminals v/ith no

detrimental effect on winch or moior.

5.

Connect red battery cable

to

positive_

battery terminal.

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"THOMAS"

EWSOOO

12 VOLT ELECTRIC WTNCH KIT

INSTALLATION OF HAND CRANK MODEL

winches equipped with ihe optional hand crank require a 2" hole to be drilled in the bumper bar in line with the shaft extending from the winch motor gear box.

This hoie will ailow access for the crank handle.

(Use hole saw or similar drill.)

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"IHQtvtAL,EWqqoo 12 voLT ELECTRtc WtNcH KtT

INSTALLATION OF WIRE ROPE

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Lay out rope in straight line, ensuring thar there are no kinks.

2.

Secui'e rope end

in rvinch cirum and tighten 3/g,, grub screw provided.

3. lnse.t pendant control into

|

4.

|

piug receptacle on control box.

Engage dog clutch and wind rope evenly

instructions for further details.)

I

5. lt is advisable

on to,sinch cjrum.

(See operating

to have your vehicle engine operating at fast idle to provide charging for the electrical system when carrying out this operation.

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