Gigglepin GP100 Manuel utilisateur
GP100 Owners Manual
Serial numbers GP1001001 onwards
www.GigglepinWinch.com
+44 (0)1732 463600
This is your GP100!
This GP100 has been hand crafted to your personal specification.
It is ready for a life of pulling hard.
But every winch is different, so tell us about you winch story and
what you do with your GP100
What is your Winch Adventure?
Let us know through our email or social media!
If you need any advice or spare parts don’t hesitate to get in touch
Serial Number
TopHousing Ratio
Drum Length
Short
Standard
Long
Motors
Solenoid
Hurricane Fitted
Yes No
MBS Fitted
Yes No
Notes
Built By
Build
Date
GigglepinWinches @GigglepinWinches
1. Introduction Page 1-3
a. What’s in the Box 1
b. How do I Fit my GP100 2
2. Application information Page 3-7
a. Rope 3
b. FreeSpool 4
c. Using Your GP100 4
d. Electrical 5-6
e. Brakes (including MBS) 7
3. Rigging and Winching Advice and Tips Page 8
a. Common Winch Hand Signals 9
b. Winch Remotes and Radios 9
4. Winch Maintenance Page 10-11
a. Maintaining Your Winch 10
b. Maintaining Your Rope 11
c. Top Tips for Your GP100 11
5. Warranty Page 12
6. Contact Information Page 12
7. Technical Data Page 13-23
a. TopHousing Diagram 13-14
b. LowerHousing Diagram 15-16
c. Winch Wiring Diagram 12V 17
d. Winch Wiring Diagram 24V 17
e. Winch Wiring Diagram OverVolting 18
f. FreeSpool and Solenoid Wiring Diagram 18
g. Winch Wiring Diagram 12V Fitted With MBS 19
h. Winch Wiring Diagram 24V Fitted With MBS 19
i. Winch Dimensions –Short Drum 20
j. Winch Dimensions –Standard Drum 21
K. Winch Dimensions –Long Drum 22
l. GP100 FairLead Mounting Underwound 23
m. GP100 FairLead Mounting Overwound 23
8. Glossary Page 25
9. Ratio Information Page 26
Table of Contents
The Gigglepin GP100 competition winch has been designed and built to give you the highest
levels of performance and reliability in a demanding world. Using the best materials and
designs that set it apart from all of its competitors, it is the standard to which others aspire.
Our winches have been built to give our end user total reliability in the toughest situations,
and supply unequalled power and speed at those critical moments.
This manual will provide you with the information that you require to install, use and
maintain your Gigglepin winch. These are shown below are shown throughout the manual.
Warning –Procedures which must be followed precisely in order to avoid risk of personal
injury.
Caution - This calls attention to procedures which must be followed to avoid damage to
winch components.
Note –This calls attention to methods which make a job easier or gives helpful hints.
The GP100 should be respected and used correctly.
Winches are not designed to lift, support or transport personnel.
1
Congratulations on the purchase of this GP100 Winch!
When you open the box you will find the following inside -
- GP100 built to your specification
- Winch Activation Pack which includes -
- On/off Switch
- Switch Cover for FreeSpool Operation
- Air Solenoid
- Connectors
- 6 Metres of 6mm Airline
- PTFE Tape
- Instruction Manual
- Sticker Pack
- T-Shirt
1. Introduction
a. What’s in the box
The GP100 has 18 symmetrical M12 mounting bolts giving it superior winch security in the
toughest of situations. When fitting your GP100 winch a minimum of six retaining bolts on
one face must be used at all times.
Note - The four missing mounting bolts and washers from the front of your winch are used
to secure the winch to the shipping pallet.
If possible Gigglepin recommend using two of the three mounting faces to hold the winch
securely, and using twelve mounting bolts where possible. Gigglepin recommend the use of
winch mounts made from a minimum of 8mm steel plate. Rear mounting bolts should not go
into the casing more then 20mm.
Gigglepin DO NOT recommend the use of tubular style winch mounts or wide mouth fairleads.
Your GP100 arrives fitted with two aluminium BraceBars to the rear of the winch. We recommend
that the BraceBars are retained where possible, unless the rear mounting points are to be used.
The GP100 is best mounted standing upright. However it can be mounted at various different
angles, but we recommend this must not be less than 20 degrees from horizontal, so as not to
affect gearbox operation and to prevent oil pooling in the TopHousing.
The Winch can also be mounted in a reverse position, but care must be taken to install the
Fairlead and rope in the correct position.
Caution - We do NOT recommend the winch is mounted laid flat.
Warning - Please remember that winch mounts need to be strong and securely fastened to
the vehicle or platform. Weak or bent mounts could result in equipment failure and
possible personal injury.
Fitting your Fairlead
You must fit the Fairlead to the correct location dependant on how your winch is installed.
With the winch in the upright (Section 7, Page 25) position, the FairLead needs to be fitted to
the lower front mounting points. If using the winch in a reverse position, the FairLead would
need to be mounted at the top (Section 7, Page 25).
It is also very important that the 3x M8 support bolts are used (Not used on short drums).
These can be fitted in two ways -
- Drill and tap your winch mounting plate, then trim the bolt to the correct length so it does
not interfere with winch rope. Note - This is our recommended method.
- Drill a hole through your winch mount and use the nuts and bolts supplied.
After fitting your FairLead, make sure there are no sharp edges on the mount that might
damage your winch rope.
2
A GP100 winch is designed to move a load at ground level or up or down an incline. It is not
designed for, nor intended for hoisting.
A GP100 winch is not designed to be used to lift or move people.
A GP100 winch is for intermittent use and is not designed for continuous use.
If the winch motors become hot, allow the winch motors to cool before continuing to winch.
If the winch stalls during operation, stop pulling! DO NOT continue to apply power to the
winch. This can damage your winch and your electrical system.
Re-evaluate the rigging, check for obstruction and double-line if required.
2. Application Information
b. How do I fit my GP100
3
GP100 Winches are designed to be operated using synthetic winch ropes (we do not
recommend the use of steel cables with this winch).
The GP100 winch is designed to be used in the upright position and the rope should be
installed from under the drum. This is called “Under wound”.
If the winch is mounted back to front (in a reverse position) the rope will be installed over the
top of the drum to allow the drum to rotate in the correct direction so the brake still works.
This is called “Over wound”.
Note - From the top = over wound. From the bottom = under wound.
Caution - the use of steel rope is not recommended.
Fitting a Rope to a GP100
The GP100 winch drum is nylon coated for durability and has a welded loop on one side.
- If the winch is fitted in an upright position, pass the synthetic rope through the Fairlead and
under the drum.
- Bring the rope around the back of the drum and over the top. Then pass the end of the rope
through the retaining loop.
- Tie a simple stop knot and pull tight.
- Your rope is now secure and ready to spool the rope on to the winch drum.
- When retrieving the rope in a no load situation it is often advisable to pulse the winch so
the motors do not over rev.
-Be sure the rope is distributed evenly and tightly on the drum.
Warning - Over revving when retrieving rope in a no load scenario can cause premature
motor failure.
Caution - GP100 winches are very fast, be sure to be standing at least two metres from the
winch, always wear gloves and make sure there are no loops in the rope or debris that could
catch your hands.
Rope Care and Use
Synthetic ropes are waterproof, float and are easier to handle than steel cable, however
debris can become caught in the strands, so gloves must be worn AT ALL TIMES.
Synthetic ropes do need to be cared for - follow these simple rules to increase rope longevity
and safety
- Never use on rocks without protection.
- Avoid constant High UV exposure.
- Keep ropes clean and dry.
- Check ropes for damage before and after use.
- If the rope is damaged, pinched, frayed or defective in any way, this will reduce the load-
carrying capability and should be replaced or repaired immediately.
- ALWAYS wear protective gloves when handling any winch rope.
a. Rope
Over wound Under wound
4
GP100s are fitted with an air FreeSpool mechanism. The FreeSpool mechanism allows fast
removal of the rope from the winch without having to engage the motors.
This can be remotely controlled using switches (supplied) or remote controls (supplied
separately). The winch comes supplied with an electric air solenoid control valve, switch and
red safety cover for this purpose (air switches are also available if required).
Follow the simple diagram for fitting the FreeSpool control solenoid and operating switch and
pipe work. (Section 7, Page 20)
When mounting the switch, try to mount it in a position where it is easily seen and cannot be
knocked accidently.
When using the FreeSpool follow these simple rules to ensure positive operation -
1.Before disengaging the free spool, be sure there is no load on the winch or cable.
2.When removing cable from the drum, take care not to accidently knot the rope.
3.After re-engaging the FreeSpool we recommend that you run the winch ‘out’ approximately
one metre and then ‘in’ to allow the FreeSpool mechanism to engage fully before applying load.
Note - Wiring diagrams can be found in Section 7 Technical data. (Page 15)
Warning - The FreeSpool should only be operated when the winch motors are not turning.
Warning - Operating the FreeSpool when the winch is under load or spinning freely could
cause damage to the operating parts and cause personal injury.
b. FreeSpool
Gigglepin winches are very fast and powerful and require respect during use.
Here are a few tips and techniques that will help you get the most from your winch.
1. Place your winch switches in a location where they are easy to use and see, also
somewhere they cannot be knocked easily.
2. NEVER put your limbs close to the FairLead or near the winch during operation.
3. Always make sure you use a secure winching point/ground anchor.
4. Do not stall your winch, if your winch should slow down or near stalling, STOP. Check for
obstructions under or in front of your vehicle or possible faults with your electrical system.
5. Always allow the winch to stop turning before switching in a different direction.
6. When winching, try to keep your wheels turning at the same speed as the winch. This will
help aid traction and help get the most from the winch.
7. Always keep the winch line under tension this will help to eliminate the chance of over
spooling or ropes becoming wrapped around the winch, which to could lead to breakages
or premature rope failure.
8. Do not allow the cable to ‘Bunch’ on the drum this could lead to the tie bars being bent or
in the worst case actually breaking the winch casing and or damaging the rope.
9. Ensure power to winch is isolated before touching or handling any part of the winch.
c. Using your GP100
5
Your GP winch comes prewired and ready to use. It only requires heavy power, heavy earth
(ground) and switching wires to be connected.
Note - Please see below for exact requirements.
Note - Full wiring diagrams available in Section 7.
12 Volt Systems using 12v motors and solenoids
The GP100 winch requires a heavy 12v feed using a minimum of 50mm² cable. This needs to
be connected to the red M8 terminal on the rear contactor and preferably via a large 250amp
(continuous) cut off switch (see picture below).
The heavy earth connection needs to be a minimum of a 50mm² cable and connected to the
bottom of the motors using the M8 fixings supplied. This should return to the battery for best
results.
You then need to connect the red and green solenoid switch wiring. We recommend that you
fit a momentary on/off/momentary on style toggle switch inside the cab within easy reach of
the driver and ideally mounted next to your FreeSpool switch. A 12v switching feed is
required and should be fused.
We suggest using no less than a 65amp 12v alternator and recommend using Odyssey PC1500
or PC1700 batteries, although other gel and AGM type batteries designed for high discharge
are also suitable.
Caution - Electrical systems are only as good as their connections. Use high quality cables
and battery terminals. Gigglepin can supply a large range of components and premade
cables for any winch install. If you are unsure of your vehicles suitability please contact
Gigglepin.
Caution - Beware of smaller 100amp kill switches as they can burn out.
24 Volt Systems using 24v motor and 24v solenoids
The GP100 winch requires a heavy 24v volt feed using a minimum of a 50mm² cable. This
needs to be connected to the red M8 terminal on the rear contactor (solenoid) and preferably
via a large 250amp (continuous) cut off switch (see picture above).
The heavy earth connection needs to be a minimum 50mm² cable and connected to the
bottom of the motors using the M8 fixings supplied. This should be returned to the battery
for best results.
You then need to connect the red and green solenoid switch wiring. We recommend that you
fit momentary on/off/momentary on style toggle switches inside the cab within easy reach of
the driver and ideally mounted next to your FreeSpool switch. The switching feed required is
24v if using 24v solenoids and should be fused.
We suggest using no less than a 50amp 24v alternator and recommend using Odyssey PC1500
or PC1700 batteries, although other gel and AGM type batteries designed for high discharge
are also suitable.
Caution - Electrical systems are only as good as their connections. Use high quality cables
and battery terminals. Gigglepin can supply a large range of components and premade
cables for any winch install.
d. Electrical
Gigglepin recommend using a Durite 250 amp Rated Isolator & Removable
Key (0-605-50)
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