Installation Instructions for Marine Winches

Part Numbers:

• XLT 7.0
• XLT 10.0

Tools Required:

• Adjustable Wrench
• 3/8” Ratchet
• 9/16” Socket
• 9/16” Combination Wrench

Step-by-Step Instructions:

Safety Before Installation:

1. Read, understand, and follow all instructions.
2. Inspect all parts, ensuring no damage or missing components.

Winch Installation:

1. Mounting Preparation:

   • Select a mounting location capable of supporting the maximum pulling capacity.
   • Ensure the winch frame is properly aligned, with the strap exit parallel to the bow eye when the boat is loaded.
   • Use three 3/8”-16 Grade-5 carriage bolts, washers, and locknuts, torqued to 28-30 ft-lbs.
   • Minimum mounting surface area: 4.5” x 6”.

2. Hawse Fairlead Installation:

   • Use an aluminum hawse fairlead to minimize friction with the strap.
   • Install 6” away from the bow eye for proper alignment.

3. Under-Wind Strap:

   • Ensure the strap is wound from the bottom of the drum to prevent damage.

Wiring Instructions:

1. Use a 12V battery with a minimum of 650 cold-cranking amps.
2. Route the cables avoiding sharp edges, heat sources, and moving parts.
3. Use the correct wire gauge based on cable length:
   • 5 ft: 7 gauge
   • 10 ft: 6 gauge
   • 15–25 ft: 4–2 gauge
4. Secure cables with zip ties and avoid loose connections.

Wireless Remote Setup:

1. The remote comes pre-paired.
2. Turn on the remote and check the indicator light:
   • Solid blue: Paired and ready.
   • Blinking blue: Re-pair needed.
3. Pairing steps include holding LINE IN/OUT buttons while reconnecting the black terminal.

Operation:

1. Pulling a Load:
   • Engage the clutch fully before use.
   • Avoid side pulls and shock loads.
2. After Use:
   • Wash with mild soap and water, then dry before storing.

Maintenance:

1. Inspect the strap and hook for wear or damage.
2. Keep the winch and controls free of contaminants.
3. Lubricate gears with Shell EP2 grease or equivalent as needed.
4. Replace worn or damaged parts immediately.

Specifications:

• XLT 7.0:
  • Max Boat Weight: 7,000 lbs.
  • Power Source: 12V DC
  • Amp Draw: 160 amps
  • Strap Size: 2” x 15’
• XLT 10.0:
  • Max Boat Weight: 10,000 lbs.
  • Power Source: 12V DC
  • Amp Draw: 200 amps
  • Strap Size: 2” x 15’

Safety Notes:

• Never exceed rated capacities.
• Always maintain a minimum of 3 strap wraps on the drum.
• Avoid submerging the winch in water.
• Ensure no body parts are near the load path during operation.

Warranty Information:

• Coverage: Limited lifetime warranty on the winch; 5 years on electrical components.
• Exclusions: Normal wear, improper installation, misuse, and alterations.
• For complete warranty instructions, please download the full installation PDF.

For Technical Support: Our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.

WARNING: Failure to follow these warnings and instructions may result in property damage, serious injury, or death.

Installation Instructions for Tongue Jacks

General Installation Notes:

• Ensure no interference from the tow vehicle, tongue, ground, or other mounted accessories, both while stationary and in motion.
• Verify proper clearance for all positions, including handle swing and swivel, before and after installation.

Tools Required:

• Torque wrench
• Ratchet set

Step-by-Step Instructions:

Bolt-On Rack Jack Installation:

1. Place the gear housing on the tongue and insert supplied bolts into the holes corresponding to tongue width.
2. Position the mounting bracket below the tongue, ensuring the flat surface is against it.
3. Secure bolts with locknuts and torque to 25 ft-lbs.

Bolt-On Mounting Bracket Instructions:

1. Confirm the correct mounting hole pattern for your tongue size.
2. Align the jack against the tongue and position mounting straps on the opposite side.
3. Insert bolts through the mounting bracket and straps, ensuring the upper bolts rest on the top of the tongue and lower bolts are close to the bottom without exceeding a 1/16" gap.
4. Secure with locknuts and torque to 25 ft-lbs.

Snap Ring/Bolt-Through Instructions:

1. For snap ring models, place the jack bracket over the mount and fully seat the snap ring into the groove.
2. For bolt-through models, align the bushing and bolt with the jack bracket and mount. Tighten the locknut to minimize movement.

A-Plate Mounting Instructions (Bolt-On or Weld-On):

1. All welding must be done by an AWS-certified welder.
2. Align the jack and foot with the coupler and weld using a 3/16" fillet weld.
3. Bolt the jack A-plate to the coupler using 3/8-16 grade-5 bolts and torque to 15-20 ft-lbs.
4. Weld the support plate to the bottom of the trailer frame using a 3/16" fillet weld.

Direct-Mount Instructions:

1. Position the jack at the desired location and weld 1" in two places on both sides of the jack using a 3/16" fillet weld.

Maintenance:

1. Lubricate internal gearing and bushings with automotive grease annually.
2. Apply lightweight oil to all moving components such as handles, screw stems, and caster assemblies.
3. Flush the jack with fresh water in marine environments and reapply lubricant.

Safety Notes:

• Fully retract and rotate the jack before towing.
• Avoid exceeding rated capacities for the jack, footplate, or caster wheel.
• Do not adjust the drop foot or leg under load.
• Avoid side forces to prevent jack failure.

Warranty Information:

• Coverage: 5 years for Bulldog® and Fulton® products; 1 year for Pro-Series® products.
• Exclusions: Damage due to misuse, overloading, or improper installation.
• For warranty assistance, visit www.trailerjacks.com or call 877-869-6690.

Additional Information:

Attention: This is a summary of the installation procedure. For complete installation instructions, including diagrams and detailed manufacturer information, please download the full installation PDF.