STANDARD GEARBOX - 185:1

RED Winches

AIR BRAKE FITTED ON ALL OPTIONS

OX MOTOR FITTED ON ALL OPTIONSFOR THE ULTIMATE POWER BEHIND YOUR WINCHING

This winch is a RED WINCHES designed product, whose designs have undergone extensive testing. The end user can now enjoy a professional highly engineered, precision, high performance electric winch capable of operating in the most demanding of situations.The small compact size combined with its pulling power and billet CNC housings make it an ideal winch for maximum impact when faced with minimal installation space

EXPLORER-2STANDARD GEARBOX - 185:1

Drawing not to be reproduced or distributed in any format or method without specific permission from Redstart//Design.

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Telephone: +44 (0)1460 67744Email: [email protected]

WINCHTYPE WINCH

DESCRIPTION:

RED WinchesTECHNICAL MANUAL

ULTIMATE PERFORMANCE WINCH

EXPLORER2 STD LOW LINE, SINGLE MOTOR, 12V / 24V DCAIR BRAKE, FREESPOOL

CONTENTS

WINCH MANUAL COVER1.

CONTENTS PAGE2.

WINCH DIMENSIONS3.

WINCH OVERVIEW DIAGRAM4.

WINCH EXPLODED DIAGRAM5.

WIRING CONNECTION SCHEMATIC6.

WINCH FREESPOOL DIAGRAM7.

STANDARD GEARBOX ASSEMBLY8.

OX MOTOR DIAGRAM9.

BRAKE ASSEMBLY10.

WINCHING INFORMATION11.


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RED WinchesCONTENTS

ULTIMATE PERFORMANCE PRODUCTS

RED WINCH EXPLORER 2 - FEATURES AND COMPONENT PARTS

258

190 220

254.0

114

.5

626

181 191

M12 FIXINGS12.9 RATED

STD GEARBOX 185:1

ADV GEARBOX 284:1

TITAN GEARBOX 352:1


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RED WinchesWINCH DIMENSIONS


RED WINCH EXPLORER 2 - TECHNICAL MANUAL

AIR FREESPOOL ASSEMBLYOPTIONAL EXTRA

ASSY DRG: EXP2-MA-04_PF

6mm TUBE REQUIRED TO FEED PISTON BODY

WINCH CONTROL BOXALBRIGHT MOTOR CONTROLLERAIR SOLENOID FOR AIR BRAKE

ULTIMATE BRAKE FORYOUR WINCHAIR BRAKE ASSEMBLY FITTED TO END OF GEARBOX

HAWSE FAIRLEADALUMINIUM - CNC MACHINEDWITH LARGE RADIUS TOEXTEND ROPE LIFE

COPPER BUS BARSFOR THE ULTIMATE TRANSFER OF POWER

THE MIGHTY OX MOTORVERY POWERFUL MOTORPROVIDING HIGH SPEED AND HIGH TORQUE FORALL WINCHING SITUATIONS

ENGINEERED DRUMSUPPORTED BY PRECISIONSEALED ROLLER BEARINGS


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RED WinchesWINCH OVERVIEW DIAGRAM



9

10

11

6

1

4

2

8

14

13

12

5

7

EXPLORER 2 - STANDARD

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 EXP2-MA-01 EXPLORER 2 WINCH BODY ASSY 1

2 EXP2-MA-02_STD EXPLORER 2 GEARBOX ASSY-STANDARD 1

3 EXP2-MA-03 CONTROL BOX ASSEMBLY - EXPLORER 1

4 EXP2-MA-04 EXPLORER 2 FREESPOOL ASSEMBLY 1

5 EXP2-MA-06 DRIVE COLLAR ASSY 1

6 RWM-MA-01 OX MOTOR ASSEMBLY 1

7 EXP2-MD-05 EXPLORER-2 DRIVE SHAFT - STD 1

8 EXP2-MD-17 END PLATE 1

9 EXP2-MD-18 EXPLORER FAIRLEAD 1

10 M12 FORM C WASHER 4

11 M12 x 30 M12 x 30 CAP HD SCREW 4

12 M12 x 35 M12 x 35 CAP HD SCREW 2

13 M4 x 10 M4 x 10 SKT BUTT HD 8

14 98203 SINGLE ROW, DEEP GROOVE BEARING 1


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RED WinchesWINCH EXPLODED DIAGRAM



CAIR BRAKELINE 6mm (SUPPLIED FITTED)

OX MOTOR12v OR 24VCAN BE SUPPLIED

DETAIL CSCALE 2 : 3

6mm AIRLINE FROM ONBOARDTRUCK SYSTEM, COMPACT ARB OR EQUIVILENT COMPRESSORMIN AIR PRESSURE 4.5 BAR (60 PSI)

VEHICLE EARTHCONNECTIONM4 STUD, WITH NUTSUSE RING TERMINALAND CONNECT TO BATTERY OR VEHICHLE EARTH

WINCH IN 12VSUPPLY FROMROCKER SWITCHON YOUR DASH

WINCH OUT 12VSUPPLY FROMROCKER SWITCHON YOUR DASH

CONTROL VOLTAGE LABELOF THE ALBRIGHT ANDAIR SOLENOID INSIDE BOX (12V or 24V LABEL HERE)

WIRING CONNECTION SCHEMATIC

ENSURE POSITIVECABLE LUG DOES NOTTOUCH ANY SURROUNDINGPARTS OR MOTOR BUZZ BARS

EARTH CONNECTIONFROM BATTERY CAN GOON EITHER ONE OFTHESE M8 THREADEDHOLES70mm2 CABLE TO BE USED

WHEN USING WIRLESS REMOTECONNECTION TO WINCH OUT / WINCH IN STUDSNOT REQUIRED. EARTH CONNECTION STILL REQUIRED

POSITIVE 12V CABLEFROM BATTERY TO BECONNECTED HEREM8 FEMALE THREAD70mm2 CABLE TO BE USED


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RED WinchesWIRING CONNECTION SCHEMATIC



E

E

M3 GRUB SCREW USED TOFIX WITH THREAD LOCTITE

6MM TUBE REQUIRED

SECTION E-E

USE GASKET SEALERUNDER HEAD OF BOLTS & DOWN BOLT HOLES

B

EXP2-MD-16_PF

O-RING-804O-RING-804

EXP2-MD-15_PF

O-RING-2.4-31.6

ENTEX-72

EXP2-MD-14

ENGAGE DRUM: ROTATE AND LOWER •

DRUM FREESPOOL: LIFT AND ROTATE TO•INITIATE DRUM FREESPOOL MOVEMENT

FREESPOOL ASSEMBLY


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RED WinchesWINCH FREESPOOL DIAGRAM



BEARING

24T

24T

18T

18T

DRIVE

VIPER-MD-25_2

VIPER-MD-25_2

VIPER-MD-26

EXP2-MD-19

EXP2-MD-13

EXPLORER 2 / STANDARD

INTERNAL SPUR GEAR

ANNULUS RING

A

A

SECTION A-ASCALE 1 : 1


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RED WinchesSTANDARD GEARBOX ASSEMBLY



M8 THREAD EARTH CONNECTIONS - 3 OPTIONS FOR POSITION

O-RING IN END PLATE

WARNINGNever allow the OX motor to 'over-speed' or run ina no-load situation for too long as the armature could become damaged through revolving too fast

171.5

BRUSH PACK IN FRONTOF MOTOR

90.0

149

.0

M6 GRUB SCREWS FITTEDTO PLUG HOLES

125.0

M8 TERMINALS

With the appropriate battery and alternator system, these OX motors will provide tremendous pulling power and a very high drum speed at no-load when respooling the rope back on to the drum.

OX MOTOR DIAGRAM


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RED WinchesOX MOTOR DIAGRAM



AIR FEED FOR BRAKEFROM WINCH AIRBRAKE SOLENOID VALVE

ABU-MD-02

N228

N230

ABU-MD-03

MN036X2.5

C1300-070

ABU-MD-04

ABU-MD-06

ABU-MD-08

1206621_AMTE-M-H-M51X

153097_QSLV-1_8-6-I1X

Springs apply pressure to a steel disc which then applies pressure to the brake disc and its material when the winch is not in use. This applies the brake and stops the winch drum from moving under load and from spooling out the rope.


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RED WinchesBRAKE ASSEMBLY



This winch is part of a range of winches produced by RED Winches Ltd that are designed for high speed and high power. This winch will pull rope onto its drum quickly and with power. If operated without care and attention this winch could easily damage fingers, hands and in some cases eyesight.The winch is powered by DC voltage, in most cases 12v, but also 24v systems can be used to power the winch. The current draw on this DC voltage can be high so care and attention must be taken when operating the winch that the electrical power to the motors is not exposed to the operator.The winch should only be operated by a person who has been authorised to do so or has been trained to operate it safely.

Safety - Explorer2 Winch

Safety Instructions - Explorer2 Winch

The Winch

Set-up Procedure

The winch is an excellent choice when it comes to speed and power for electric winching.It has been designed specifically for high performance and durability.The winch can give you speeds of 50m/min for the standard model, and 65m/min with the Hornet ‘Overdrive’ gear set (available separately) giving you a choice so you have the power and speed when you need it. The winch body is CNC machined from high grade heat treated aerospace aluminium from solid billets. Its patented brake system offers something previously unavailable on a winch and ensures the winch stops instantly when your finger it taken off the winch control button.

You can also have the Explorer2 come with the Overdrive Kit which makes it 1.5 times faster...his is free if you specify it at the time of ordering.

Springs apply pressure to a steel disc which then applies pressure to the brake disc and its material when the winch is not in use. This applies the brake and stops the winch drum from moving under load and from spooling out the rope.

An air solenoid for the air brake is fitted next to the motors at the top of the winch. This is fed by an air supply from the ARB compressor.When you winch in or out you energise your Albright motor solenoids this also energises the air solenoid valve for the brake on top of the winch. This then allows air to go into a specially designed chamber that releases the brake instantly. When you remove your winching finger from the controls the air solenoid dumps the air and the springs apply the brake disc onto the brake pads.

This means compared to normal winching you do not get overrun or excess rope causing snatching and jerking as the vehicle takes up the slack rope that has been spooled out. This design has been submitted for full patent and is currently protected and patent pending.

The electrical power of this winch is currently supplied a single OX Motor, 12v (7HP). These are supplied normally with a 12v supply from your vehicle onto the high efficiency copper busbar assemblies found on top of the motor. The high power Albright motor solenoid is used to switch direction of the motor and at the same time provide a feed to the 12v brake system via their signal terminals.

The winch air brake system:

The drum is mechanically driven by a solid steel hardened clutch plate. This is a very tough hardened plate.The clutch plate is driven from the gearbox by a solid steel central shaft passing through the middle of the drum. The drive system has been built for strength and durability.

All our winches are now supplied with Plasma Locks to hold the synthetic rope onto the drum, proven method and very reliable.It is a nice simple solution to ensure you always have the minimum amount of line wraps on your winch drum.With the Plasma Lock installed you can pull your rope line out with confidence that it won't leave you without any line on the drum!The Plasma lock has been designed for a variety of line gauges and you can feel confident that at least 8-10 wraps remain on your drum, reducing greatly the chances of a slippage.The Plasma Lock is made from double thickness, heavy duty bright red webbing and is 150mm x 40mm (approx).

Drum

The gearbox has been specifically designed for strength, power and ease of service. All gears are manufactured from 655-M13 nickel chromium molybdenum steel and case hardened to give maximum strength (1100 N/mm²) and excellent durability. The end covers are sealed via an o-ring and groove, ensuring a watertight seal. Once the cover is removed access to all gears is possible and only takes a short time to service and re-assemble. The gearbox runs in grease not oil making it much easier to service in the field.

Gearbox

WARNING! THIS WINCH IS ONLY SUITABLE FOR WINCHING SITUATIONS / APPLICATIONSWARNING! Ensure all fasteners and connections are adequately connected or secured before using the winchMaintain the equipment in good condition (use an authorised servicing agent if required)Replace or repair damaged parts. Use genuine parts only. Unauthorised parts may be dangerous and will invalidate any warranty.Use a qualified person to lubricate if required and maintain the equipment. Before use, ensure all parts are clean and free of contamination / dirt.DO NOT use solvent cleaners to clean this winchUse the equipment in a suitable work or operational area, keep winching area clean and tidy and free from unrelated materials, and ensure that there is adequate lighting while setting and operating the winch.Keep the winch and winch rope clean for best and safest performance.The maximum line load is 4500kg. DO NOT exceed this rated capacity.When operating remove ill-fitting clothing. Remove ties, watches, rings and other loose jewellery, and contain long hair.Maintain correct balance and footing, do not over reach. Ensure the floor / ground is not slippery and wear appropriate footwear.Before using the winch check that there are no overhead or surrounding obstructions.The speed during operation must be kept steady and constant. Do not generate sudden movements or shock loads.

DO NOT use the winch for a task it is not designed to perform.DO NOT use the equipment if damaged.DO NOT exceed the rated capacity of the equipment.DO NOT use the equipment when you are tired or under the influence of alcohol, drugs or intoxicating medication.DO NOT allow untrained persons to use the equipment unsupervisedDO NOT attempt to transport a load outside JLR designated safe load / unload areas.DO NOT make any modifications to the equipment

DO NOT operate the winch and handle the synthetic rope without approved winching gloves and appropriate PSE

(1) Check winch as per the safety instructions(2) Check winch is situated correctly for the task at hand(3) Check rope is on drum securely and is not tangled(4) Check power connection to winch(5) Ensure Compressor is on and the winch has air pressure to it(6) Winch is now ready to operate

The winch can release and winch line in at 40m/m or faster, this is much faster than a normal winchThe winch gearbox has gears that are straight cut for strength and durabilityThe winch gearbox is noisier than other winches due to the rotational speeds of the gears, especially when not under load.The compressor will run and vibrate whenever it needs to topup the air in the system, the winch uses very little air to operate.This compressor could start when the winch is not being operated if the air pressure in the system drops

Startup

Q: How do I store the rope on the drum?A: Always leave the drum and rope neatly spooled after use with the rope clean and evenly layered

Q: What should I do if the winch has been used in muddy / wet / dirty conditionsA: After a prolonged dirty wet operation clean and wash the rope and clean all connections

Q: What if the winch stops while operating?A: If the winch overloads, i.e. it stops under load, release the control button immediately and assess the situation otherwise you could damage the motors. Check all electrical connections to ensure they are secure and look normal.

Q & A

Documents

STANDARD GEARBOX - 185:1