Superwinch EPI Installation Instructions

Superwinch EPI Installation Instructions
OWNER’S MANUAL
INSTALLATION • OPERATION • MAINTENANCE
SAFETY PRECAUTIONS • REPAIR PARTS
EP/EPi6.0 and EP/EPi9.0
12 & 24 Volt DC Electric Winch
!
CAUTION
READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION
AND OPERATION OF YOUR SUPERWINCH PRODUCT.
Superwinch, Inc.
Winch Drive
Putnam, CT 06260
U.S.A.
Tel. (860) 928-7787
Fax (860) 963-0811
90-10902 Rev B 5/19/04
Superwinch, Ltd.
Abbey Rise, Whitchurch Road
Tavistock, Devon PL 19 9DR
England
Tel. +44 (0) 1822 614101
Fax +44 (0) 1822 615204
ROLLING LOAD CAPACITIES
INTRODUCTION
Thank you for purchasing an EP series winch from Superwinch. It has been designed
and manufactured to provide years of trouble-free operation. We hope you will be
pleased with its performance. If you are not, for any reason, please contact our Customer
Service Department: (860) 928-7787 USA; +44 (0) 1822 614101 England.
When requesting information or ordering replacement parts; always give the
following information:
1. Winch Part Number
2. Serial Number
3. Part Number
4. Part Description
Model
Slope
20% (11º )
30% (17º )
10% (6º )
EP/EPi 6.0 Lbs.** 29,410
kg** 13,340
20,760
9,140
15,460
7,010
7,710
3,500
EP/EPi 9.0 Lbs.** 45,225
kg** 20,514
30,600
13,880
23,500
10,659
11,573
5,250
Ratings assume a 10% coefficient of friction.
* A 10% slope is a rise of one foot in ten feet. Slope in approximate degrees is also shown above
** All loads shown are for single-line operation. Double-line operation with optional pulley block
(p/n 7750A) approximately doubles capacity of winch.
Note: Winch specifications and equipment may vary from country to country.
U N PA C K I N G
The responsibility for safe installation and operation of this winch ultimately rests
with you, the operator. Read and understand all safety precautions and operating
instructions before installing and operating the winch. Careless winch operation
can result in serious injury and/or property damage.
This carton contains the following items. Please unpack carefully.
Read instructions before beginning.
Throughout this manual, you will find notations with the following headings:
Description
!
DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
!
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
!
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. This
notation is also used to alert against unsafe practices.
Always Use
Handsaver
Keep clear of winch,
wire rope and hook
while operating
Never use winch
to lift or move
people
Quantity
Winch assembly with wire rope
Handsaver
Remote switch
Clevis hook, roller fairlead, pulley block
Owner’s manual
1
1
1
1
1
F E AT U R E S
1. Electric Motor – 12V series
wound and 24V series wound.
2. Braking – Automatic loadholding brake.
Drum – Fabricated steel
Freespool Clutch – Operated by
an easy action lever which
The following symbols on the product and in the Owner's manual are used:
Read Owner's
Manual
Never use
winch to hold
loads in place
disengages the ring gear to allow
the wire rope to be pulled out
without using electric power.
Remote Switch – 15' handheld
pendant switch assembly.
DIMENSIONS
Note: Indicates additional information in the installation and operation
procedures of your winch.
Correct installation of your winch is a requirement for proper operation.
Congratulations on your choice!
2
254(10.1")
63.5(2.5")
63.5(2.5")
EPi6.0
154(6.06")
EPi9.0
179(7.05")
Superwinch is not responsible for printing errors inadvertently made in the production of this manual.
250(9.84")
130(5.1")
114(4.49")
Please Note: Winch is designed primarily for intermittent applications. This winch
is not designed to be used in hoisting applications and Superwinch does not warrant
it to be suitable for such use. Please contact our Customer Service Department for
further information.
100% (45º )
229(9.01")
254(10.00")
EPi6.0 568(22.36")
EPi9.0 593(23.35")
114(4.49")
160(6.30")
159(6.26")
4- 11(0.43")
114(4.49")
229(9.01")
EP6.0
154(6.06")
EP9.0
179(7.05")
254(10.00")
160(6.30")
4-11(0.43")
159(6.26")
EP6.0 - 568(22.36")
EP9.0 - 593(23.35")
3
GENERAL SAFETY
I N F O R M AT I O N
INTERMITTENT DUTY
An electric winch is like any othe motor
driven power tool such as an electric drill
or saw. The electric motor should not be
allowed to become excessively hot.
Normal,precautions will extend the life
of your motor. Keep the duration of pulls
as short as possible. If the end of the
motor becomes uncomfortably hot
to touch, stop winching and allow the
motor to cool down.
If the winch
motor stalls,
do not continue to apply power
to the winch.
!
CAUTION
Brake housing
will get hot
during extended power out operation.
!
CAUTION
PERFORMANCE
EP/EPi 6.0
Wire Rope
Layer
1
2
3
4
5
EP/EPi 9.0
Max. Pulling Capacity
lbs.
kg
6,000
5,465
5,000
4,670
2722
2477
2268
2118
Load
Lbs.
kg
0
2,000
4,000
6,000
8,000
9,000
0
907
1814
2722
3629
4082
Wire Rope
Layer
1
2
3
4
5
lbs.
kg
9,000
8,190
7,500
7,010
6,570
4082
3715
3402
3180
2980
Line Speed and Amp Draw
EP/EPi 6.0
EP/EPi 9.0
Line Speed*
AMP Draw
Line Speed*
Amp Draw
FPM MPM
12V
24V
FPM MPM
12V
24V
48
23
13
10
NA
NA
14.6
7
4
3.1
NA
NA
40
170
350
440
NA
NA
24
102
210
264
NA
NA
S P E C I F I C AT I O N S
Working Load*
Wire Rope
EP 6.0/9.0
EPi 6.0/9.0
Motor Type
Motor Output 12V
Motor Output 24V
Clutch
Brake
Gear Ratio
Max. Pulling Capacity
EP/EPi 6.0
6000 lbs. (2722 kg)
EP/EPi 9.0
9000 lbs. (4082 kg)
100' x 21/64"
125' x 21/64"
Series Wound
3.6 HP
2.0 HP
Sliding Ring Gear
Auto. Load-holding
156:1
Series Wound
4.6 HP
2.6 HP
Sliding Ring Gear
Auto. Load-holding
156:1
44
15
11
9
7.5
6.4
13.4
4.6
3.4
2.7
2.3
2
33
110
200
230
260
350
15
55
100
115
130
210
Your winch is a very powerful
machine. Treat it with respect, use it
with caution and always follow these
safety guidelines.
The responsibility
for safeinstallation and operation of the winch and
prevention of personal injury and
property damage ultimately rests
with you, the operator. There is
no substitute for the use of good
judgement and caution in operating
a winch.
!
WARNING
The wire rope
may break before
the winch stalls. For heavy loads, use
a pulley block to reduce the load on
the wire rope.
!
WARNING
1. Do not maintain power to the
winch if the motor stalls. Overloads
can damage the winch and/or the
wire rope and create unsafe operating conditions. FOR LOADS OVER
2/3 RATED CAPACITY, WE
RECOMMEND THE USE OF THE
OPTIONAL PULLEY BLOCK TO
DOUBLE LINE THE WIRE ROPE
(Figures 1). This reduces the load on
the winch and the strain on the wire
rope by approximately 50%. If
attaching back to vehicle, attach to
the frame or other load bearing part.
The vehicle engine should be
running during winch operation
to minimize battery drain and
maximize winch power and
speed. If considerable winching is
performed with the engine off, the
battery may be too weak to restart
the engine.
* Based on first layer performance
4
Single Line
Figure 1
2. AFTER READING AND
UNDERSTANDING THIS
MANUAL, LEARN TO USE
YOUR WINCH. After installing the
winch, practice using it so you will
be familiar with it when the need
arises.
3. DO NOT “move” your vehicle to
assist the winch in pulling a load.
The combination of the winch and
vehicle pulling together could
overload the wire rope and the
winch itself.
4. KEEP WINCHING AREA CLEAR. Do
not allow people to remain in the
area during winching operations.
ALWAYS STAND CLEAR OF WIRE
ROPE/HOOK AND WINCH. IN THE
UNLIKELY EVENT OF ANY COMPONENT FAILURE IT‘S BEST TO BE OUT
OF HARM‘S WAY.
5. INSPECT WIRE ROPE AND EQUIPMENT FREQUENTLY. A FRAYED
WIRE ROPE WITH BROKEN
STRANDS SHOULD BE REPLACED
IMMEDIATELY. Always replace
wire rope with the manufacturer‘s
identical replacement part (see
Replacement Parts List). Periodically
check the winch installation to
ensure that all bolts are tight.
6. USE HEAVY LEATHER GLOVES when
handling wire rope. DO NOT LET
WIRE ROPE SLIDE THROUGH YOUR
HANDS EVEN WHEN WEARING
GLOVES.
Double Line
5
GENERAL SAFETY
I N F O R M AT I O N
( C O N T. )
7. NEVER WINCH WITH LESS
THAN 5 TURNS of wire
rope AROUND THE
WINCH DRUM since the wire rope
end fastener will NOT withstand
a load. Your winch wire rope has
a ten-foot red “warning indicator” on each end. The “warning
indicator” at the winch end
warns you that the wire rope is
near or less than 5 turns. The
“warning indicator” at the hook
end of the wire rope warns you
that the hook is approaching the
winch. ALWAYS USE THE HANDSAVER when guiding the wire
rope in or out (see Figure 2). As
you use your winch, the red paint
will wear off due to normal use.
When this happens, renew the
red paint as it is a safety feature of the winch.
GENERAL SAFETY
I N F O R M AT I O N
( C O N T. )
Wrong
14. NEVER OBSCURE THE WARNING
INSTRUCTION LABELS.
Right
Figure 3
10. Lay a heavy blanket or jacket
over the wire rope near the
hook end when pulling heavy
loads (Figure 4). Should a wire
rope failure occur, the cloth will
act as a damper and help prevent the rope from whipping.
Raise the hood of the vehicle for
added protection.
Figure 4
11. NEVER USE YOUR WINCH
FOR LIFTING PEOPLE OR
MOVING PEOPLE.
12. Your winch is not intended for
overhead hoisting operations.
Figure 2
8. KEEP CLEAR OF WINCH,
TAUT WIRE ROPE AND
HOOK WHEN OPERATING WINCH. Never put your
finger through the hook. If your
finger should become trapped in
the hook, you could be injured.
Never guide a wire rope onto
the drum with your hand.
9. NEVER HOOK THE WIRE ROPE
BACK ONTO ITSELF. You could
damage the wire rope. Use a
nylon sling (Figure 3).
6
13. AVOID CONTINUOUS PULLS
FROM EXTREME ANGLES as this
will cause the wire rope to pile
up at one end of the drum
(Figure 5). This can jam the wire
rope in the winch, causing damage
to the wire rope or winch itself.
Right
Figure 5
Wrong
15. Always operate winch with an
unobstructed view of the
winching operation.
16. Equipment such as tackle, hooks,
pulley blocks, straps, etc. should
be sized to the winching task
and should be periodically
inspected for damage that could
reduce their strength.
17. NEVER RELEASE FREESPOOL
CLUTCH WHEN THERE IS A LOAD
ON THE WINCH.
18. STORE THE REMOTE PENDANT
ASSEMBLY IN A SAFE PLACE
when not in use to prevent use
by children or other unauthorized persons who could injure
themselves or others.
19. DO NOT OPERATE WINCH
WHEN UNDER THE INFLUENCE
OF DRUGS, ALCOHOL OR
MEDICATION.
20. ALWAYS UNPLUG THE REMOTE
PENDANT BEFORE WORKING IN
OR AROUND THE FAIRLEAD OR
WINCH DRUM (THE DANGER
ZONE) so that the winch cannot
be turned on accidentally.
21. When moving a load, slowly
take up the wire rope slack until
it becomes taut. Stop, recheck
all winching connections. Be
sure the hook is properly seated.
If a nylon sling is used, check the
attachment to the load.
23. DO NOT USE THE
WINCH TO HOLD
LOADS IN PLACE. Use
other means of securing loads
such as tie down straps.
Superwinch offers a wide variety
of tie downs. Contact your local
Superwinch dealer.
24. USE ONLY FACTORY APPROVED
SWITCHES, REMOTE CONTROLS
AND ACCESSORIES. Use of nonfactory approved components
may cause injury or property
damage and could void your
warranty.
25. DO NOT MACHINE OR WELD
ANY PART OF THE WINCH. Such
alterations may weaken the
structural integrity of the winch
and will void your warranty.
26. DO NOT CONNECT WINCH
TO EITHER 110 VOLT AC HOUSE
CURRENT OR 220V MAINS AS
WINCH BURNOUT OR FATAL
SHOCK MAY OCCUR.
27. Never allow shock loads to be
applied to winch or wire rope.
28. Always operate your winch in
an underwound orientation
only.
Underwind
Overwind
Overwind
Fig. 2
22. When using your winch to move
a load, place the vehicle transmission in neutral, set vehicle
parking brake, and chock all
wheels.
7
Automobile batteries contain
gasses which are flammable and
explosive. Wear eye protection
during installation and remove all
metal jewelry. Do not lean over
battery while making connections.
I N S TA L L AT I O N
!
MOUNTING YOUR WINCH
Improper
mounting
can cause personal injury.
WARNING
!
3. Route the long red and black color
coded wires to the battery. To
ensure against insulation abrasion
and/or cutting, apply several layers
of electrical tape where wiring may
come in contact with sharp parts on
the vehicle. Attach the red color
coded wire to the battery positive
terminal, and reattach the terminal
to the battery.
Improper mounting could
damage your winch and void
warranty.
MINIMUM ELECTRICAL
REQUIREMENTS
For 12 Volt winches, a 60 amp
alternator and battery with 440
cold-cranking amperes capacity are
the minimum recommended power
sources. If the winch is in heavy use,
an auxiliary battery is recommended.
Under some circumstances, it may
be appropriate to install additional
circuit protection devices (circuit
breakers). If in doubt, seek
appropriate advice.
Superwinch recommends that all inch
electrical systems can be readily and
quickly isolated from their electrical
supply in the event of an emergency.
The winch electrical system should
always be isolated when the winch
is not in use.
1. Install mounting kit or structural
support for winch.
2. Mount the winch to a mounting
kit base plate or to the mount
that you designed.
EP 6.0/9.0
4. Turn the freespool clutch lever to
the “free” position. Pull several
feet of wire rope off the drum.
Return the clutch lever back to
the “Engage” position. Plug in
remote pendant control. Push
button momentarily to check
wire rope drum rotation direction. If drum rotates in the wrong
direction, recheck your wiring.
WARNING
PENDANT OPERATION
Cable Out
Figure 6
Cable In
Figure 7
The handheld pendant switch
activates a solenoid that activates
power to the winch motor.
To connect the pendant control,
remove the cover on the plug
receptacle and insert the plug end
of remote switch. The plug on the
pendant control cord is keyed and
will fit into the socket only one
way.
The switch trigger returns to the
“Off” position when released.
To change direction, move the
toggle in the other direction.
The switch
assembly
must be kept free of dirt and
moisture to ensure safe operation.
!
CAUTION
To prevent
unauthorized
use of the winch, remove pendant
control and store in a clean dry area
such as the glove box.
!
EPi 6.0/9.0
8
If your vehicle is equipped with side
pole terminals, it may be necessary
to obtain auxiliary side terminal
bolts from your local auto parts
dealer to make these connections.
Connect the black color coded wire
to the battery negative terminal,
then connect the terminal to the
battery.
Do not substitute any
strength grade weaker than
SAE Grade 8 (ISO 10.9).
!
WARNING
CAUTION
9
PULLING OUT THE WIRE ROPE
The wire rope has been installed on
your winch under minimal load at
the factory. The wire rope must be
respooled onto the drum under
load so that the outer layers will
not draw down into the inner ones
thereby damaging the wire rope.
Rotate the clutch lever to the “Free
position as shown in Figure 8. If
there is a load on the wire rope, the
clutch lever may not turn easily. DO
NOT FORCE THE CLUTCH LEVER.
Release tension on the wire rope by
jogging out some of the wire rope,
then try releasing the clutch. Pull
out the wire rope and secure to
anchor or load. Check that there
are at least five (5) turns of wire
rope left on the drum. Re-engage
the drum by rotating the clutch
lever to the “Engaged” position
(see Figure 8).
Lever must be in
the engaged
position and locked before winching.
!
at all times. A good practice is to
rewind the wire rope under tension after each use. One way to
do this is to attach the hook to a
stationary object at the top of a
gradual incline and winch your
vehicle up the incline.
2. DO NOT ALLOW WINCH MOTOR
TO OVERHEAT. Remember, the
winch is for intermittent use only.
During long or heavy pulls the
motor will get hot. The internal
parts will be hotter than the case.
To check the motor temperature,
stop winching and carefully touch
the motor case, if the motor is
uncomfortable to touch, allow
the motor to cool before continuing. KEEP THE ENGINE RUNNING
TO RECHARGE THE BATTERY during this break.
3. To maximize winch and wire rope
life, use a pulley block to double
line heavier loads (Figure 9).
CAUTION
a. This is the start
of a kink. Wire
rope should be
straightened.
b. Wire rope was
pulled and loop
has tightened into
a kink. Wire rope
is now permanently damaged and
must be replaced.
c. Result of kinking is that each
strand pulls a different amount causing strands under
greatest tension
to break and
reduce load capacity of wire rope.
The wire rope
must be replaced.
a
b
c
Figure 10
6. EQUIPPING THE WINCH WITH A
ROLLER FAIRLEAD will substantially
reduce wear on the wire rope
during angle pulls (Figure 11).
The rollers eliminate heavy rubbing
and abrasion to the wire rope.
Figure 11
Figure 9
MAINTENANCE
Figure 8
TIPS FOR EXTENDING THE LIFE OF
THE WINCH
1. KEEP A TIGHTLY WOUND WIRE
ROPE DRUM. Do not allow the
wire rope to become loosely
wound. A loosely-wound drum
allows a wire rope under load to
work its way down into the layers
of wire rope on the drum. When
this happens, the wire rope may
become wedged within the body
of the windings damaging the
wire rope. To prevent this problem, keep the wire rope tightly
and evenly wound on the drum
10
4. The pull required to start a
load moving is often much
greater than the pull required
to keep it moving. AVOID
FREQUENT STOPPING AND
STARTING during pull.
5. PREVENT KINKS BEFORE THEY
OCCUR.
Periodically check tightness of
mounting bolts and electrical connections. Remove any dirt or corrosion that may have accumulated on
the electrical connections.
Repairs should be done by
Authorized Superwinch Repair
Centers ONLY. Do not attempt to
disassemble the gearbox.
Disassembly will void warranty.
LUBRICATION
The gearbox and drum bearing are
permanently lubricated with a high
performance gear lube.
REPLACING THE WIRE ROPE
Figure 12
Never substitute a heavier or lighter
wire rope. Never use rope made of
any other material other than wire.
Always replace damaged wire
rope with manufacturer’s
identical replacement part (see
Replacement Parts list). Pass attaching
end of wire rope through the fairlead (if
equipped) and attach it to the drum.
When inserting the wire rope into
the drum, insert it into the correct
end of the hole provided (Figure
12). Tighten the set screw securely.
It is important that the wire rope
be wound tightly onto the drum.
A good way to do this is to attach
the wire rope hook to a fixed object
at the top of a slight incline, then
winch the vehicle up the incline.
When wire rope is removed from
the drum, as in bringing the hook
to the load, the freewheel feature
of the winch should be used.
BRAKE ADJUSTMENT
Over time, the load-holding brake
in your winch will wear. Should you
find the load beginning to slip,
adjustments can be made to the
brake mechanism as follows:
1) Loosen the 3 retaining bolts and
remove the brake cover. (Ref.#25
Figs. 13, 14)
2) Remove the two retaining C-rings.
(Ref.#35 Figs. 13, 14)
3) Insert washers to maintain a spacing
of .090" +/- .010" between the C-ring
grooves and the brake actuating cam.
(Ref.#21 Figs. 13, 14)
4) Re-install the two C-rings and
brake cover.
11
EP SERIES WINCH
A S S E M B LY
REPLACEMENT
PA R T S L I S T
1
29
33
Brake
Assembly
21
35
12
55
4
25
10
7
16
17
18
19
38
27
2
41
30
36
9
5
45
56
57
3
4
26
44
53
40
49
48
51
8
50
47
12
Part Number
12 VDC Motor EP/EPi6.0
24 VDC Motor EP/EPi6.0
12 VDC Motor EP/EPi9.0
24 VDC Motor EP/EPi9.0
Motor Support Rack
Gear Support Rack
Drum Bushing
Drum (3" diameter on 09332 and 09334 only)
Gear Box
Connecting Socket
1st Shaft
1st Pinion
1st Stage Carrier
1st & 2nd Ring Gear
2nd Stage Carrier
3rd Stage Carrier
3rd Ring Gear
3rd Washer
90-30500
90-30501
90-30502
90-30503
90-40500
90-40501
90-14500
90-30517
90-30504
90-20500
90-20501
90-20502
90-30505
90-30506
90-30507
90-30508
90-30509
90-20503
90-20504
20
21
23
24
25
27
35
50
51
53
55
56
57
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
90-30510
Brake Clutch Base
Brake Cam
Cone Brake Disc
Spiral Spring
Brake Cover
Bearing
C-Rings (2 per assembly)
Hardware Kit
29
30
31
32
33
26
36
37
40
41
42
43
44
45
46
47
48
49
Qty
Clutch Sleeve
Clutch Lever
Pressed Spring
Clutch Knob
Spring Pin
Brake Assembly
11
32
42
Figure 13
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
Freespool Assembly
20
15
57
43
56
13
23
37
24
14
46
1
6
18
17
16
38
37
19
53
31
Freespool
Assembly
Reference
Number
90-14501
Hex. Bolt (6 per kit)
Hex. Bolt (3 per kit)
Hex. Bolt
Hex. Bolt
Hex. Bolt
Bearing
C-Ring
Anit-leak Seal (2 included)
Wire Rope
Roller Fairlead
Mounting Hardware
Clevis Hook
Remote Switch Assembly
Handsaver Strap
Snatch Block
Remote Switch Socket
Upper Solenoid Box
Solenoid 12V
Solenoid 24V
Solenoid Mounting Plate
Lower Solenoid Box
Motor Lead Wire Set
Tie Bar
Tie Bar Screw
Spring Washer
90-20513
90-14502
90-20505
90-20506
90-30511
90-14503
90-20507
90-33450-01
87-31120
90-20508
90-25048-01
90-41144
90-14452
90-14454
90-24051
90-41145
90-20511
90-20509
90-14504
90-14505
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
13
REPLACEMENT
PA R T S L I S T
Reference
Number
17
6
18
38
1
16
55
37
19
55
31
Freespool
Assembly
EPi SERIES WINCH
A S S E M B LY
Brake
Assembly
21
23
13
20
27
16
17
18
19
38
10
4
9
5
30
36
11
32
54
46
20
21
23
24
25
27
35
26
4
48
3
58
49
53
52
51
56
8
59
41
57
40
45
44
29
30
31
32
33
26
36
37
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Clutch Sleeve
Clutch Lever
Pressed Spring
Clutch Knob
Spring Pin
90-30510
Brake Clutch Base
Brake Cam
Cone Brake Disc
Spiral Spring
Brake Cover
Bearing
C-Ring
Hardware Kit
43
14
90-30500
90-30501
90-30502
90-30503
90-40500
90-40501
90-14500
90-30517
90-30504
90-20500
90-20501
90-20502
90-30505
90-30506
90-30507
90-30508
90-30509
90-20503
90-20504
Brake Assembly
42
Figure 14
Part Number
12 VDC Motor EP/EPi6.0
24 VDC Motor EP/EPi6.0
12 VDC Motor EP/EPi9.0
24 VDC Motor EP/EPi9.0
Motor Support Rack
Gear Support Rack
Drum Bushing
Drum (3" diameter on 09332 and 09334 only)
Gear Box
Connecting Socket
1st Shaft
1st Pinion
1st Stage Carrier
1st & 2nd Ring Gear
2nd Stage Carrier
3rd Stage Carrier
3rd Ring Gear
3rd Washer
Freespool Assembly
25
12
7
2
15
47
35
53
51
52
37
24
50
14
29
33
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
90-14501
Hex. Bolt
Hex. Bolt
Hex. Bolt
Hex. Bolt
Hex. Bolt
Bearing
C-Ring
Anit-leak Seal (2 included)
Wire Rope
Roller Fairlead
Mounting Hardware
Clevis Hook
Remote Switch Assembly
Handsaver Strap
Snatch Block
Control Box Left Cover
Control Box Right Cover
Electric Box
Rubber Clamp
Hex. Bolt
Hex. Bolt
Spring Washer
Solenoid 12V
Solenoid 24V
Motor Lead Wire Set
Remote Switch Socket
Bolt
Nut
Rubber Cover
90-20513
90-14502
90-20505
90-20515
90-30511
90-14503
90-20507
90-33450-01
87-31120
90-20508
90-30512
90-30513
90-30516
90-20510
90-14506
90-14507
90-14508
90-14453
90-14455
90-20512
90-25058
90-23032-22
90-23149-06
90-25046
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
15
TROUBLESHOOTING
CHART
W A R R A N T Y R E PA I R C E N T E R S
If a problem arises, contact your nearest
Superwinch dealer or repair center.
USA
Symptom
Possible Cause(s)
Corrective Action
Motor will not operate
or runs in one direction
only
1. Damaged or stuck
solenoid; most likely
caused by not holding
the inner nut to keep the
stud from turning when
attaching wire to solenoid
1. CAUTION: Disengage
clutch before performing this test to prevent
powering the wire rope
drum. If a solenoid sticks
once, it is likely to stick
again and must be
replaced immediately.
Tap solenoid to free
stuck contacts. Check
by applying voltage to
the small solenoid terminal. Be sure solenoid
is grounded back to
source. A solenoid that
is not stuck will make an
audible “click” when first
energized
2. Replace Switch
3. Check for poor connecttions. CAUTION: Always
use two wrenches
(spanners). (See Figure 10)
4. Replace or repair motor
5. Check the ground path
between battery
negative and solenoid base
2. Switch inoperative
3. Broken wires or bad
connection
4. Damaged motor
5. Solenoids not grounded
Winch will not shut off
Motor runs extremely hot
Motor runs but with
insufficient power or
line speed
1. Solenoid stuck “on”
1. If solenoid sticks on,
reverse direction and hold
trigger switch on until the
power lead can be disconnected. A safety on-off
switch is available as an
accessory
1. Long period of operation
2. Damaged motor
3. Damaged brake
1. Allow to cool
2. Replace or repair motor
3. Replace or repair brake
1. Weak battery
1. Recharge or replace
battery. Check charging
system
2. Use larger gauge wire
2. Battery to winch wire
too long
3. Poor battery connection
3. Check battery terminals for
corrosion. Clean as
required
4. Poor ground
4. Check and clean connections
5. Damaged brake
5. Repair or replace brake
Motor runs but drum
does not turn
1. Clutch not engaged
1. Engage clutch
Winch runs backwards
1. Motor wires reversed
2. Solenoids wired incorrectly
1. Recheck wiring
2. Recheck wiring
Will not hold load
16
1. Excessive load
1. Reduce load or double line
2. Worn or damaged brake
2. Repair or replace brake
Superwinch Inc.
Winch Drive
Putnam, CT 06260
phone: 860-928-7787
repair@superwinch.com
Electric Motor Repair
2010 North 4th Street
Minneapolis, MN 55411
phone: 612-588-4693
Berens & Associates
124 Hegenberger Loop
Oakland, CA 94621
phone: 800-540-2858
berens94621@yahoo.com
Zorko’s Alternator Service
241 Wells Road
Home, PA 15747
phone: 800-468-5055
zasapw@microserve.net
Electric Motors of Iowa City
50 Commercial Court
Iowa City, IA 52246
phone: 319-354-4040
emic4040@aol.com
Outdoors Plus
128 Regional St.
P.O. Box 1349
Port Aux Basques, NF A0M 1C0
709-695-7533
Bobcaygeon Auto and Marine
91 Main St.
Bobcaygeon, Ont. K0M 1A0
705-738-2317
MAP Bracebridge
19 Taylor Rd.
Bracebridge, Ont. P1L 1W3
705-645-8785
MAP Fenelon Falls
165 Lindsay St.
Fenelon Falls, Ont. K0M 1N0
705-887-6232
Central Electric Motor Rewind
#1-1960 Windsor Rd.
Kelowna, NC V1Y 2Y3
250-860-4415
jnelsoncentral@netscape.net
CANADA
Delta Tool Repair Limited
114-7533, 135th St.
Surrey, BC V3W 0N6
604-591-3230
Demand Electric
228-39th St. N.E.
Calgary, AB T2E 2M5
403-230-2709
Ted's Power Tool Repair
426-44th St. East
Saskatoon, SK S7K OW1
306-934-6155
Harold Supply
3 Southerland Ave.
Sudbury, Ont. P3C 3A7
705-761-4455
Bob's Electric Truck Servise
845-B Macdonald Ave.
Regina, SK S4N 2X5
306-721-4148
Explora Industries Ltd.
9605-5th Ave.
Edmonton, AB T6E 0B2
780-430-8591
Off Road Canada
251-12th St. "B" North
Lethbridge, AB T1H 2K8
403-327-7722
Dayworth Sales
1 Saunders Rd. Unit 2
Barrie, Ont. 9A7 9A7
705-726-7778
Gary's Starter & Alternator
P.O.Box 7 Site 4
RR 1 Mount Uniacke B0N 1Z0
Contact: Gary Thorne
902-757-2388
Les Equipment Twin
10401 Parkway Blvd.
Ville D’Anjou, PQ H1J 1R4
514-353-1190
Buffalo Industries
251-253 Princess Street
Winnipeg, Manitoba R2C 1M1
204-942-1951
Power Plus Tool Repair
57 Millenium Ave.
Moncton, NB E1E 2G2
560-855-8665
Muskoka Auto Parts
11 King William St.
Huntsville, Ont. P1H 2K8
705-789-2321
Lou Dennis Auto
Hiway 11 South
Sundridge, Ont. P0A 1Z0
705-384-5345
Power Blitz Mftg. & Maintenance
577 Edgeley Blvd. Unit 6
Concord, Ont. L4K 4B2
905-669-8209
ali@powerblitz.com
Bruce's Recreaction
92 Balbo Dr.
Shoal Harbour Nfld A5A 4A8
709-466-3355
Atlantic Recreation & Marine
5 School St.
Sydney, Nova Scotia
B1S 3G1
902-567-1697
sbidart@thearm.ca
UNITED KINGDOM
Superwinch, LTD
Abbey Rise, Whitchurch road
Tavistock, Devon PL19 9DR
+44 (0) 1822 614101
W O R L D W I D E Contact your Local
Superwinch Distributor or callSuperwinch.
17
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