Installation Instructions for Trailer Winch

Part Numbers:

• FW20000101

Tools Required:

• 9/16" socket or wrench
• Torque wrench

Step-by-Step Instructions:

Mounting the Winch:

1. Ensure the mounting surface is equal to or larger than the winch frame footprint.
2. Use three (3) supplied 3/8” diameter grade-5 carriage bolts and lock nuts.
3. Torque the bolts to 28-30 ft-lbs.
4. Verify the winch is securely mounted before use.

Installing the Handle Roller Assembly:

1. Assemble the handle roller according to the provided diagram.
2. Tighten the lock nut to 20-25 ft-lbs using a 9/16” socket.

Adjusting the Handle:

1. The handle can be adjusted for length (6” to 9”) and for right or left-hand drive:
   • Remove the bolt and washers on each side of the drive shaft.
   • Push the hex shaft 1/2”-3/4” through to the opposite side, keeping internal gears aligned.
   • Attach the handle bolt and washers on the handle side and torque to 22-25 ft-lbs.
   • Repeat for the other side of the shaft without overtightening.

Attaching the Winch Strap:

1. Use the strap anchor provided with the winch.
2. Pass the strap loop under the cross bolt and through the anchor slot.
3. Insert the strap anchor into the strap loop and pull tight.
4. Maintain a minimum of three complete wraps of strap on the drum.

Using the Winch:

1. Letting Out Line/Load:
   • Firmly grip the winch handle.
   • Disengage the ratchet plunger or engage it in the reverse direction.
   • Slowly let out the strap while ensuring the ratchet plunger is engaged to hold the load when paused.
2. Taking In Line/Load:
   • Engage the ratchet plunger in the forward/loading position.
   • Turn the handle to wind the strap properly onto the drum.
   • Pause by ensuring the ratchet plunger holds the load.

Maintenance:

1. Inspect and replace any damaged or worn parts before use.
2. Keep gears, ratchet contact points, and shaft bushings lubricated with light oil or grease.
3. Clean the winch occasionally with mild soap and water to maintain its performance and appearance.

Safety Notes:

• Never release the crank handle unless the ratchet plunger is fully engaged.
• Do not operate the winch with slippery, wet, or oily hands.
• Avoid standing alongside the winch or guiding the strap with hands.
• Do not exceed the rated capacity stamped on the winch.
• Use tie-downs to secure boats during towing; winches are not designed for this purpose.
• Ensure a loud clicking sound is heard from the ratchet when pulling a load.

Specifications:

• Capacity: Based on direct line pull on the third layer of the strap on the drum.
• Handle Force: Requires a maximum of 45 lbs to pull the rated load.

Warranty Information:

• Limited Lifetime Warranty:
  • Covers material defects and workmanship under normal use.
  • Does not cover normal wear, misuse, or improper installation.
  • For complete warranty instructions, please download the full installation PDF.

Compliance References:

• Conforms to EN-12100-2:2003 Safety Machinery standards and Machinery Directive 98/37/EC.

Technical Support:

For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.

Installation Instructions for Tongue Jacks

General Installation Notes:

• Confirm no interference from the tow vehicle, tongue, ground, or other mounted accessories during use.
• Verify 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 holes corresponding to the 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.