Thomas Winch Owner's Manual

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THOMAS EWBCOOElectric 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

THOMAS

;:'ilblication No. 5O

III CONGRATULATIONS

Y6u have purchased the finest winch available today.

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

conditions.

t 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.

I 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

r also.

\Ye hope that this informaiion contributes in a positive way to your enjoymen'. o{

your chosen four 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 - 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

improper use of the winch.

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

for such purposes.

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THOMAS EWSOOO 12 OR 24 VOLT DC ELECTRIC WINCH

GENERAL INFORMATION

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

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

CAUT|ON for Safety Reasons. lt is not possible to Disengage the Dog Clutch onthe Winch Under Load. Switch off Winch by use of pendantcontrol. Youi-Winch will automatically stop, wherr pressure is reieased from $Jinch Siaritch.

CAUTION. Do not leave pendant control (operating suritchi plugged into ControlBox receptacle when Winch is not in use, or when using the Hand Crank (where

this option is instailed) on your "Thomas" Winch. CAUTION: Ensure WlnchMotor 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 thefurtherest, not neai-est point when winching.

(b) The Grubscrew in the Winch Drum is NOT designed to with-stand the Line Pull that the Winch is able to deliver. Therefore it is mostimportant that no winching is ever undertaken unless there are 8 wraps ofwire rope on the drum at all times.

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TECHNIOUES !-E OPERATION

lt is advisabre to famiriarise yourserf with the operation of your THoMAS winch

before You reallY need to use it'

l-:-re best way is to set up a few test runs in various situations'

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

a:d have gained some confidence in your winch and its use' winching operations

rr;ii beco;'ne second nat'ure'

Remember that your winch wiil not only puil you up a slope, it will also lower

you <Jown. You can also pull (or lower) another vehicle or a load while your

vehicle is secured in a stationaiy position'

-i-he {oliorving illustrations show a fevr winching techniques' Try ihem yourself

ancj trren use the knorvieclge you have gainecl to practise in more demanding

s:iu ations.

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SINGLE LINE PULL

YourTHoli4ASwinchisratedaccordingtoitsSlNGLELlNEPULLcapacity on the first Iayer of cable on the drum'

As the layers increase in number, the single line pull rating is progressively

reduced.

MULTIPLE LINE PULL

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.

The time taken to winch a given cJistance is increased proportionately (i.e-

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 with not less than 3 inches

(76 mm) separation'

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BURIED ANCHOR

Anyreasonablylargeandsolidobjectcanbeusedasananchorifnothingmoresuitable is available'

*Buryalogsufficientlydeeptoensurethatitcannorbedislodgedduring

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

Bury your spare tyre horizontallyabout half a metre down'

A boat sand anchor makes an ideal buried anchor'

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

Useashieldtoprotecthimagainstinjuryshouldther.ebeacablebreak.

Locatethetowropeasfardownthehandleaspossibleformaximumleverage.

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::'.';'ENTIONAL

',',,'ching is acccmplished using a suitable existing anchor point located

.n close proximity to the extelrded centre line of the vehicle'

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EARTH ANCHOR

Very often' suitable existing anchor points are not available'

Threeorfourtimberorstar-picketstakesburieduprightinlinewiththe

towing direction make a workable substitute'

AttachthewinchcabletoaslingorropewhichhasbeenfirmlysecuredtoALL stakes.

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 a slope.

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

unit if P.T.O. winch'

g. DON'T USE the winch cable as a tow rope or move the vehicle to pull a

loaci on the winch. Cable breakage may result.

9. DAMAGED CABLES should be replaced immediately.

10. 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 extendedcentre 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 as possible to ground ievel as this gives

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.

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THOMAS EWSOOO 12 OR 24 VOLT DC ELECTRIC WINCH

SUGGESTED WINCHING PROCEDURE

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.

Look along where your Winch Rope is laying and cr:ck that the Rope will not

foul etc., when winching is carried out.

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

Remember your switch is of the Rocker Type. P|essure on the bottom of the

SwitchwillresultinaWl!operation.P.:ssureonthetopoftheswitch 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.

To assist your battery, start engine if possible selec: neutral gear and keep itat 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.

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.

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)

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. Remember, 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'

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'

Always pull in as straight a line as possible.

After winching is completed keep pressure on the rcpe 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

roller. Make sure rope is well tensioned on drum (and cannot shake loose

when travelling over rough terrain). Remove pendant control from winch

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 INONE DIFIECTIONONLY

MOTOR FIUNSEXTR EM E LYHOT

MOTOFI FUNS,BUT WITH INSUF-FICIENT POWEF,OR WITH LOWLINE SPEED

MOTOR FIUNS, BUTDRUM DOES NOTTU BN

MOTOR WI LL NOTOPE RATE

POSSIBLE CAUSE

(1 ) Defective solenoid or stucksolenoid.

(2) Defective switch

(3) Broken wire or bad connection

(1) Armature dragging

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

(1 ) lnsufficient Battery

(2) Battery to winch cable toosmali

(3) Bad connection

(4) I nsufficient charging system

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

(1 ) Defective solenoid or stucksolsnoid

(2) Defective switch

(3) Oefective motor

(4) Loose cmnections

CORRECTION

(1 ) Jar solenoid to free contacts. Checkby spplying '12 volts to coil terminal(it should maks an audible click wh€nenergized).

(2) Disengage winch clutch or rsmovearmatu16 l€ad. Bemove switch plugfrom hood. Raise connrctor covgron hood and with a screw driver, shortthe bottom two pins. Solenoid shouldclick. Short the two left hand pins.The other solenoid should operate. lfboth solsnoids operate, check for abroken wira in switch cabla.

(3) Check for loose connection on switchand switch connector. Spread pinsapsrt slightly if nrcessary.

(1 ) Chect< bushings for excessive wsar.Replace if worn badly.

(2) Replace if cause not d€termined.(3) Allow to cool.

( 1 ) Check battery terminal voltage underload. lf 10 volts or lsss, replace orparallel another battery to it.

(2) Check battery to ground (chassis)cable. Must be No. 2 or larger.

(3) Check battery terminals for corrosion,clean and grease,

(4) Replace with larger capacity chsrgingsystem.

(1) lf clutch engaged butsymptom stillexists, it will be nocessary to disas-senble rryinch to determine causeand repair.

{1 ) Jar solenoid to free contacts. Checkbv applying 12 volts to coil terminal(it should make an sudible click whenenergizad).

(2) Disengage winch clutch or r€movearmBture lead. Bemove sw.itch plugfrom hood. Raise connector coveron hood and with a screw driver,short the bottom two pins. Solenoidshould click.Short the two left hand pins. Th€other solenoid should operate. lf bothsolenoids operate, check for a brokenwire in switch cable.

(3) lf solenoids oper6te, check for voltageat armature post, if present, replacemotor.

(4) Tighten connections on bottom sideof hood and on motor.

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TROUBLE SHOOTING GUIOE (continusd)

CONDITION POSSIBLE CAUSE CORRECTION

CLUTCH JUMPS OUT (1) Clutch jaws have ben damaged (1) Replace clutch and drum, or theuNoER LOAD or worn by partial engagement clutch and clutch ring which is

on previous hesvy pulls bolted to ihe drum.

CLUTCH BINDS (1) Dry or rusty shaft (1) Clean and lubricate.(2) Keys pulled out of shape (2) File oif burrs or replace keys.

CLUTCH (1 ) Loose set screw (1 ) Tighten'INOPERATIVE (2) Lost key (2) Fleplace.

(3) Bent yoke (3) Straighten or replace.

OI L LEAKS F ROM ( l ) New seal (1) New sesls sometimes l€ak untilHOUSINGS seated to shaft.

(2) Saal damag€d or'ilorn (2) Fleplace'(3) Too much oil (3) Drain excess oil per lubrication

i nstruc ti o ns.(4) Damaged gasket (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

HEAVY DUTY SNATCH BLOCKS

Single and multi sheave blocks in a

variety of sizes.

CABLE HARDWARE

A complete range of cable hardr,";are

is stockei.

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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

l@I 1. Remove existing bumper bar and support brackets from chassis side raiis.

t2. -Bolt

the 4,,x3,,x12%" extensionanglessupplieC ontooutsiCe cf chassis side rails

I using eight 1" x 318" bolts' nuts 6p6i 5pring washers supplied '

I 3 :::ilJi,,1:iT,?",:::,i:ili:r:;,il;;$::::lli.T:'lhen

b'''l n posi"n

I4.Replacebumperbarsupportbracketsonoutsideofextensionanglesusingeight

I 1" x 3l8" bolts, nuts and spring washers supplied'

I 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 ofthe gear box.

FITTING INSTRUCTIONS

1. Remove bumper bar and tow hooks.

2. Remove triangular bumper bar support 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%" xlk"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 if desired'

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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 situationabove electric motor in position provided.

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(a) Ensure good earth contact between base of conirol box anC 'ryinch irarie.

It is important to remember that all the',vinch conti-ol por,ver flows tnrcuch thrrryinch frame and control box.

Clean the winch frame in the area under r,vhich the control box is to be i:ositionecjby 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 is necessary toensure that full battery power is available to the winch motor.

I Connections must be kept clean and tight'

An earth strap, connected from one of the three bolts securing the electric mctorto 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 as an optional extra ifrequired.

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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 sideof the vehicle.)

1. Slip the rubber boots supplied over the black, blue and vellow cables beforemaking 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 maintaingood earthing or electrical contact.

2. Connect black cable (armature) to terminal stamped ,,A,, on rvinch motor.

3. Connect blue cable to terminal stamped "F2" on winch motcr-.

4. Connect yellow cable to terminal stamped "Fl" on winch motor.

NOTE; F1 and F2 terminals are side by side. Should an alteration of the runningrotation of the winch be required to suit a particular winch installation,the blue and vellow wires can be changed over on their terminals with nodetrimental effect on winch or motor.

5. Connect red battery cable to positive (+) battery terminal.

This assumes electrical polarity of the vehicle is neqative to earth. i.e. the frame ofthe 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. thef rame of the vehicle. .

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"MUa$1EWB00o 12 voLT ELECTRTC WTNCH KtT

WIRING INSTRUCTIONS - TOYOTA

(For any front mountjng installation where the winch motor is situated on the passengerside of the vehicle.)

1. slip the rubber boots supplied over the black, blue and vellour cables beforemaking 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 maintaingood earthing or electr.ical contact.

2. Connect black cable (arnrature) from control box to terminal stamped ,,A,,on

'ayinch motor.

conriect biue cabre to terminar stamped "F2" on erectric motor.

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

NorE: 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 nodetrimental 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 drilledin 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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1. 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 piug receptacle on control box.

| 4. Engage dog clutch and wind rope evenly on to,sinch cjrum. (See operatinginstructions for further details.)

I5. lt is advisable to have your vehicle engine operating at fast idle to provide charging

I for the electrical system when carrying out this operation.

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