* Powered by Vehicle 12 or 24 Volt Battery * Reversible Motor and Power Package

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DYNAMICS

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WINCH OWNERS

MANUAL

MODELS T200 - 12 VOLT

T200 - 24 VOLT

GENERAL SPECIFICATIONS

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9,000 Lbs. Capacity of Dependable Power

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Powered by Vehicle 12 or 24 Volt Battery

*

Reversible Motor and Power Package

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Six Splined Stress Proof Alloy Steel Shaft

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Dependable Sliding Clutch Operation

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Clutch Operated for Free Spooling

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Self Locking Worm Gear Holds Securely

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Heavy Duty Anti-Friction Bearings

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Compact Low Horizontal Design

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Attractive Durable Black Finish

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Kits Available for Most 2 & 4-WD Vehicles

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Remote Switch with 10 Foot Plug in Cord

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Open Horizontal Drum Allows Even Cable Laying MAILING: P.O. Box 1464 Victorville, CA 92392

SHIPPING: 8981 State Highway 395 (North of 115) Hesperia, CA 92345

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Part

CD CD

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Item No. aty. Description

1 105 1 Clutch Houstrl-g \ 2 102 1 Lever Screw '\ ,

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3 103 2 Key 4 100 1 Clutch Lever

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5 137 2 Grease Fitting 6 107 1 Shifter Yoke

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7 108 1 Yoke Set Screw 8 140 1 Set Screw 9 114-8 1 Drum. 8"

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9 114-11 1 Drum.11" ...

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10 146 2 Drag Brake \ 11 147 2 Spring 12 117 1 Gear Housing 13 118 4 Plug 14 135 1 Gasket 15 123 20 Cap Screw 16 136 1 Cover

17 132-R 1 Gear. Right Hand 18 148 1 Retaining Ring 20 106 2 Bushing , 21 128-8 1 Shaft 21 128-11 1 Shaft 22 150 1 Thrust Washer 23 151 1 Retaining Ring 24 109 1 Clutch Dog

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\ 25 152 1 Spring

26 138-2 1 Name & Serial Plate

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27 139 1 Clutch Operation Plate 28 153 1 Cap 29 127 2 Seal 30 156-15 AIR' Shim 31 156-30 A/W Shim 32 126 1 Cap .33 142 2 Bearing Cup

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.34 143 2 Bearing Cone

35 125-R 1 Worm. Right Hand 36 122 1 Cap

37 144 8 Cap Screw 38 145 11 Washer

39 257 4 Cap Screw. Socket Hd.

40 234 1 Retaining Ring 41 232 2 Transfer Gear

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42 218 1 Housing 43 219 1 Gas~'et 44 231 1 Thrust Washer 47 229 1 Power Shaft 48 233 1 Idler Gear 49 221 3 Plug 50 222 1 Cover

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51 52 226 227 1 1 Motor Drive Gear Set Screw

53 237 3 Nut 54 200-12 1 Motor 12Vor 24V ~ 55 230 1 Key 56 260 1 Brace 80 104 1 Clutch Shaft 2 SECTION

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Part

Item No. Qty. 63' 266 1 64' 215 1 65 203 1 66 267 1 67 217 1 68 216 1 69 268 1 70 269 1 71 270 1 72 205-4 2 73 272 3 74 211 1 75 205-4 2 76 202-12 2 76 202-24 2 77 212 2 78 204 8 79 271 3 "As required Description Relay Assembly'

Control Lead Assembly' Bracket Battery Lead Switch Handle Switch Switch Lead Connector, Female Connector, Male Buss Bar Motor Lead Cover Buss Bar Relay Relay Cover Screw Terminal Relay Lead 'Includes items #65, 66, 71, 72, 73, 74, 75, 76, 77 'Includes Items #67, 68, 69, 70

AAlso supplied with thrust ball bearings when ta

-pered rollers are not available.

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MATERIAL SPECIFICATIONS

WORM - Precision machined from STRESSPROOF material, induction heat treated, ground and polished for long dependable service.

GEAR - Ductile cast for strength and durability. Best alloy for long dependable service.

CABLE DRUM - Cast malleable steel to withstand high impact and extreme loads. Drum is machined to exacting specifications, bushed with bronze busnings and enameled for protection from corrosion.

HOUSINGS - High-tensile-strength aluminum castings for lighter weight and permits best weight to strength ratio. All castings are expertly machined to exacting tolerances. Castings have durable baked black enamel finish to enhance the appearance.

BEARINGS - Heavy duty anti-friction bearings are used to handle extreme thrust and radial loads with maximum durability.

SLIDING CLUTCH - Ductile cast for strength and durability. Machined and broached to exacting tolerances for ease of operation and long dependable service. Negative draft on clutch jaws prevent disengagement under load.

SHAFTS - Machined from STRESSPROOF alloy steel with a minimum yield point of 125,000 psi. Drum shaft is 1 W' in diameter to eliminate distortion. Splined shafts prevent shearing of keys and increases clutch efficiency.

SPUR GEAR - High quality steel, hardened in all high-load areas

provide the most efficient speed reduction and smooth operation with minimum power drain and maximum dependability.

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4

II

WHITE

(FIELD 1

&

2)

GREEN}

WHITE

~g~N2JgTOR

BLACK

(ARMATURE)

(FIELD I)

RELAY

(OPEN SIDE)

RED

o

V

(BATTERY)

~YELLOW

T -266

(ARMATURE)

ELECTRICAL

Performance failure of any electric winch or accessory is caused 80% OF THE TIME BY A BAD GROUND OR A LOOSE CONNECTION. Make sure electric base plate on T-266 relay assembly is also grounded.

A. Make sure all cables are tight on both the ring connector and on stud they are attached to. Care must be taken when installing cable to motor. Nuts closest to the motor housing should be held with a wrench so stud can not turn in housing.

B. Make sure the winch itself is properly grounded - we suggest running a ground strap from the ground side of the battery directly to the winch assembly - do not attach ground strap to motor.

C. Make sure solenoid mounting base plate is properly grounded. Again the best ground is from the battery ground to the base plate (#4 gauge wire preferred).

D. Performance of an electric winch is directly dependent upon the quality and capacity of your battery and alternator. Be sure it is at full charge and up to the demand that could arise. A 70 amp/ hour battery and 55 amp alternator is the minimum required. E. When the winch is in use, the vehicle's engine should be running

at a fast idle.

F. Care should be taken when installing electric controls. Be sure wires are properly routed away from exhaust manifold, and away from any sharp edges that may cut into and weaken the insulation.

G. Electric battery shut-off switch (Part No. 1610) is highly recom-mended.

H. Do not leave control handle plugged in when winch is not in operation.

I. Mount electric relay box in dry location.

ELECTRIC LEAD

All electric cables are color coded on the ring connector where they fasten to the motor or to the battery .

• Red ring connectors will go to the battery

• Two white connectors will be attached to the Field 1 and Field 2 motor studs (studs also colored white)

• Yellow connector will go to the field motor stud (stud also colored yellow).

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ELECTRIC LEAD

CONTROL SWITCH

To connect, lift flap on control box and plug in. Move switch on handle for forward or reverse. Allow winch to come to a com-plete stop before reversing directions and NEVER KEEP POW-ER ON WHEN WINCH IS IN A STALLED SITUATION. Note: 4 wires from electric box.

1. Red goes to battery

2. White goes to field. Makes no difference which white wire goes to Field 1 or Field 2, just so they are white.

3. Yellow to armatu re

Studs on motor are also color coded.

Ring Connector on end of wire is color coded.

FIELD 1

(WHITE)

FIELD 2

(WHITE)

ARMATURE

(YELLOW)

BLACK

WHITE

BLACK

WHITE

GREEN

W

BLACK

5

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6

OIL LEVEL HOLE

IF WINCH IS MOUNTED UPSIDE DOWN

MAIN GEAR HOlJSING

USE EP90/120 GEAR

OIL APPROX. V2 PINT

j

OIL LEVEL HOLE

TRANSFER (A&B)

USE SAE 30

HOLDS APPROX 1 2 PINT

LUBRICATION

• Lubricate two grease fittings on clutch housing at regular vehicle lubrication intervals

• Check oil level in gear cases about every six months

• Use good grade of E.P. 90/120 gear oil in main gear housing - oil should just start to run from oil level hole when proper capacity is reached (do not overfill- capacity appx. % pint)

• Use good grade of SAE 30 non-detergent motor oil. Oil should just start to run from oil level hole in transfer case when proper capac-ity is reached.

NOTE: It is recommended thewinch be run forward and backward a few times monthly to dissipate and condense any moisture that may be in the electrical pack. Shift the clutch lever into neutral position and the motor will run freely without moving the cable.

CABLE

To feed out cable from winch, disengage winch clutch by moving lever to "OUT" position, as indicated by label on winch clutch housing, and pull cable out by hand or by vehicle movement. To start winching operation after feeding out and attaching cable to load to be moved, pulled or lifted, re-engage winch clutch by moving lever to "IN" pOSition. If difficulty in engaging the clutch is encountered, rotate winch drum by hand while moving clutch lever until clutch is fully engaged.

To feed out cable under power or to lower load, move button on winch control switch to "OUT" position and hold until desired amount of cable is fed out or until load is lowered.

Be sure winch clutch is fully engaged and cable is securely and safely fastened to load or anchor before attempting any winching-in operation. To winch in, move electric control switch to "IN" position and hold until load is lifted or pulled to desired position or until vehicle is free. Never keep power on when winch is in stalled situation.

When winching, pulling or lifting a load, be sure vehicle's brakes are securely applied and remain applied throughout winching operation to prevent dangerous movement of vehicle and/or load. When self-winching vehicle from stuck position, be sure parking and service brakes are not applied and that vehicle is not against an immovable object, so that no undue strain is put on your winch or vehicle.

Your Desert Dynamics winch is a worm gear type and is not equipped with any type of mechanical brake, which can be troublesome and unreliable. To hold a load when raising or lowering, just release the control switch which will stop the winch and hold the load in that position until the winch is activated again. Do not disconnect clutch while winch is under load.

It is recommended that most loads be pulled in from a "straight ahead" position. This allows the cable to wind more evenly around the drum. If the cable builds up on either side of the drum it will limit the amount of cable that can be used on that winching operation.

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WINCH CABLE

INSTALLATION

Unwind cable carefully, by rolling it

along the floor as if it were a tire, to avoid kinking.

Insert cable in hole in winch drum and tighten set screw securely. Apply about 100 to 150 Ibs. tension to cable as it is being wound onto the drum. Tension can be applied by anchoring hook end of cable to any fixed

location and pulling vehicle slowly. It is very important to make sure the

cable winds tightly, evenly and without kinks onto the drum. Keep hands away from cable and hook when operating winch. Never attempt a winching operation with less than 5 full turns of cable on the drum.

Your Desert Dynamics winch is a well manufactured and reliable product. With proper care, use and maintenance it will have a long, trouble-free and reliable life.

REMEMBER - Take good care of your DESERT DYNAMICS

WINCH AND CABLE, and ... they, in turn, will be ready to take good care of you when it really counts.

BLANKET OR HEAVY JACKET OVER CABLE - DAMPENS CABLE

~"-"---. IF IT BREAKS

NOTE - These

are only tips and are not Intended

to be instructIOns.

WARNING - Do not stand close to winch cable or between cable and vehicle when pulling with winch.

It.. It's always nice to have a large tree handy. but if you don't, you can use ...

8. One or more stakes criven in a line

and chained together.

C. You can bury a stake or log.

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liNGLE UNE

DOUBLE LINE

The pulling and safe hOisting capacity of any power winch can be increased by doubling or tripling the line as shown in the two

illustrations.

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Each time the winch line is brought around snatch block dead ended on the vehicle, anchor post, or first sheave block, the line pull is increased and line speed reduced.