This document serves as an Installation and Operator's Manual for Mile Marker electric winches, covering models SEC8 ES, SEC8 Scout ES, SEC95 ES, SEC12 ES, SEC15 ES, and PE4500 ES. It provides comprehensive instructions for safe operation, installation, and maintenance of these recovery gear products.
The primary function of these Mile Marker winches is for vehicle self-recovery and assisting in pulling loads horizontally. They are designed for intermittent use in recreational recovery situations, not for constant duty or commercial/industrial applications. The winches utilize a wire rope or synthetic rope wound around a drum, which is powered by an electric motor to pull a vehicle or object. A key safety feature is the automatic load-holding brake, which ensures that the load is maintained without requiring clutch adjustment.
Usage Features:
- Clutch Engagement/Disengagement: The winches are equipped with a clutch lever that allows for engaging or disengaging the gear train from the winch drum. In the "Disengage" or "Freespool" mode, the drum can rotate independently, allowing the cable to be pulled out manually to the anchor point. In the "Engage" position, the gear train couples with the drum for powered winching. It is crucial never to disengage the clutch while the cable is under load to prevent injuries and damage.
- Remote Control Operation: The winches are operated via a hand control plug-in. The remote control features "LINE IN" for spooling the cable back onto the drum and "LINE OUT" for extending the cable. A red Kill Switch is integrated into the remote control, which must be rotated to the "ON" position for operation and "OFF" when not in use to prevent unintended activation.
- Cable Management: Users are instructed to ensure at least five complete turns of rope remain on the drum before winching to prevent damage to the cable. When winching, the cable should be wound onto the drum properly, avoiding overlapping or gaps. After winching, the cable should be unhooked with adequate slack and re-wound onto the drum.
- Snatch Block Use: The manual details the use of a snatch block to increase pulling power and reduce the load on the winch motor. It emphasizes attaching the return cable to a tow hook or recovery eye, not directly to the winch mount, and using a clevis to secure the snatch block to a strap.
- Self-Recovery Techniques: For self-recovery, it's recommended to position the cable as straight as possible towards the anchor point. The vehicle's handbrake and footbrake should be free, and the transmission in neutral. The driver should be in the vehicle, and the steering wheel can be used to assist the process. Moving the vehicle in reverse to assist the winch is cautioned against, as it can overload the cable and winch.
- Load Capacity and Angles: Users are advised not to exceed the winch's rated load capacity. For maximum line pull, the cable direction should not exceed a 15-degree angle up or down from horizontal or a 45-degree angle left or right from straight ahead. Continuous pulls from extreme angles should be avoided as they can cause the rope to pile up at one end of the drum.
- Safety Precautions: The manual stresses keeping the winching area clear of people, wearing appropriate protective clothing and leather gloves when handling wire rope, and never operating the winch under the influence of drugs, alcohol, or medication. It also recommends laying a heavy blanket or jacket over the rope during winching to dampen potential whipping in case of cable failure.
Maintenance Features:
- Lubrication: All moving parts within the electric winch are factory-lubricated with high-temperature lithium grease, and no further internal lubrication is required for the life of the winch. The cable, however, should be lubricated periodically with light penetrating oil.
- Electrical Connections: Electrical connections should be cleaned before and after use to prevent corrosion, which can reduce performance or cause electrical shorting.
- Cable Inspection and Replacement: After every use, the cable must be inspected for damages such as kinks, broken strands, or fraying. Any damaged cable should be replaced immediately with a Mile Marker recommended replacement part, ensuring it is identical in strength, quality, lay, and stranding to the original cable. Hooking the rope back onto itself is explicitly prohibited as it weakens the cable.
- Motor Overheating: The winches are designed for intermittent use. If the motor becomes too hot to touch, operation should cease, and the motor allowed to cool for a few minutes. If the motor stalls, power must be cut off immediately. Running the winch for more than one minute at maximum rated load is not recommended.
- Initial Cable Winding: Before the first use, the entire cable must be re-wound onto the drum under a load of at least 500 lbs (227 Kg), starting with at least five wraps on the initial layer. This prevents damage to the cable from outer wraps pressing against inner wraps.
- Troubleshooting Guide: The manual includes a troubleshooting section to help diagnose and remedy common issues such as the motor not turning on, running too hot, running slowly, the cable drum not turning, or the motor running in only one direction. This guide provides possible causes and suggested remedies, including checking the safety switch, tightening connections, tapping solenoids, and replacing defective components.
- Control Box Installation: The control box can be mounted either on the winch motor or on the tie bars. Instructions are provided for both methods, emphasizing the use of appropriate tools and ensuring proper routing of battery power cables to avoid interference with vehicle parts and potential electrical shorts.
- Clocking Instructions: The gear housing can be clocked in eight different positions (0°, 45°, 90°, etc.) to allow users to position the clutch lever at their desired orientation. Detailed steps are provided for removing, repositioning, and reattaching the gear housing and its components.
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