DC POWER DRIVES
O W N E R ’ S MANU A L
INSTALLATION • OPERATION • MAINTENANCE
SAFETY PRECAUTIONS • REPLACEMENT PARTS
READ AND UNDERSTAND THIS MANUAL
BEFORE INSTALLATION AND OPERATION OF
YOUR SUPERWINCH PRODUCT.
Superwinch, LLC.
359 Lake Road
Dayville, CT 06241 USA
tel: 1.800.323.2031
fax: 1.860.963.0811
sales@superwinch.com
www.superwinch.com
61-12880 Rev A 11/08/13
Superwinch, LTD.
Union Mine Road
Pitts Cleave
Tavistock, Devon UK
PL19 ONS
tel: +44 (0) 1822 614101
fax: +44 (0) 1822 615204
sales@superwinch.net
www.superwinch.com
INTR ODUC TIO N
INTR ODUC TIO N
Thank you for purchasing a Superwinch product. It has been designed and
manufactured to provide years of trouble-free operation. Please read and
understand this Owner's Manual before using your Power Drive. If used
unsafely or improperly, there is a possibility that property damage or personal injury can result. Your safety ultimately depends on your caution
when using the product. Correct installation is a requirement for correct
operation. Pay particular attention to the Safety and Installation sections of
this manual.
Superwinch reserves the right to alter model specifications without prior
notice. Superwinch, through its continuous improvement policy reserves the
right to improve any product through changes in design or materials as it
may deem desirable without being obligated to incorporate such changes in
products of previous manufacture.
PLEASE KEEP THIS OWNER'S MANUAL WITH THE UNIT.
These instructions are designed to assist skilled technicians in the efficient
installation of the Power Drive, using the appropriate trade tools.
GENERA L DESCR IPTION
Several models of Power Drives are
available to fit your needs. Options
include different reduction ratios,
DC motor.
Each Power Drive is equipped with a
permanent magnet motor and is
designed for intermittent use only.
This means that the Power Drive
must be used for only short periods
of time and allowed to cool down.
Figure 1: Power Drive
IF THE MOTOR BECOMES UNCOMFORTABLY HOT TO TOUCH,
STOP OPERATION AND ALLOW IT TO COOL.
IF THE MOTOR STALLS, DO NOT CONTINUE TO APPLY
POWER TO THE UNIT.
2
S P E C I F I C AT I O N S
S P E C I F I C AT I O N S
Gearbox Type Right Angle
Gear Reduction Worm and Wheel
Braking Inherent-See Warning in Safety Section
Mounting Three point bulkhead, requiring three
5/16-18 UNC Grade 5 or better bolts
Output Shaft(s) 3/4 OD with 5/16 through hole and
Table 1: Specifications
3/16 keyway
Weight Motor Power
Power Drive #'s Ratio (Lbs.) Voltage (hp)
719527, 719520 90:1 10.5 12V DC 1.3
719627 90:1 11.5 12V DC 1.8
719537 90:1 10.5 24V DC 1.3
719637, 719630 90:1 11.5 24V DC 1.8
716527 60:1 10.5 12V DC 1.3
716627 60:1 11.5 12V DC 1.8
716537 60:1 10.5 24V DC 1.3
716727 60:1 12.3 12V DC 2.1
719727 90:1 12.3 12V DC 2.1
D I M E N S I O N S
⁄
6.1
L
OHL = Overhung Load
Power Drive #'s "L" Power Drive #'s "L"
719527, 719537, 716527 719630 11.6 11.0
719627, 719637, 716627 11.4
Figure 2: Power Drive Dimensions
2
1
3.1
716727, 719727
2.3
1.02
OHL
5/16
P
3/4
12.0
3
DC POWER DRIVE MODELS
12V Across Motor - 12V Models
24V Across Motor - 24V Models
(6 AWG for XXX72X)
With 10' Total of 8 AWG
12V Across Motor - 12V Models
24V Across Motor - 24V Models
(6 AWG for XXX72X)
With 10' Total of 8 AWG
300
27
330
18
245
54
245
33
1200
320
21
330
12
200
36
240
24
1200
28
30
57
78
No Load Rated Torque
Current Current Rated Torque Current Current Current Current
CW @ Output Shaft CCW @ Output Shaft CW @ Output Shaft CCW @ Output Shaft
30
96
27
64
P E R F O R M A N C EP E R F O R M A N C E
716527 90 25 73 36 750 38 170 51 145 37 190 39 190
716627 87 26 73 29 1040 35 225 48 202 30 260 54 230
716537 90 15 78 17 750 51 70 51 70 45 95 39 105
719527 66 21 57 21 790 34 130 42 117 28 165 36 155
719627 60 17 57 24 1125 28 200 39 205 25 250 42 258
719537 60 14 54 17 790 39 62 42 58 36 79 36 79
for your Power Drive.
The following performance data is shown to provide a guideline of what speed and current are expected at no load and at rated torque
Performance is strongly dependent on voltage applied to the motor. If long lengths of small diameter wire are used, performance will be
severely limited due to the voltage drop caused by the wire. The voltage at the motor should be verified to be at or greater than the
rated voltage specified in Table 2; this will allow the unit to achieve the performance values shown here. It is also important to verify that
adequate current is available to achieve these performance results.
Table 2
Power Drive #'s RPM (A) RPM (A) (in-lb) RPM (A) RPM (A) RPM (A) RPM (A)
719637, 719630 60 15 54 16 1125 32 100 32 105 28 116 27 134
719727
716727
If you require further information on the performance of your Power Drive, contact your Superwinch distributor or Superwinch customer service.
4
GENERAL SAF ETY INFO R M AT I O N
1. NEVER CONNECT YOUR POWER DRIVE TO ANY POWER SOURCE
OTHER THAN THAT SPECIFIED ON THE MOTOR. THIS CAN CAUSE
DAMAGE TO THE MOTOR AND POSSIBLY FATAL ELECTRICAL SHOCK.
2. ALWAYS DISCONNECT THE UNIT FROM ITS POWER SUPPLY PRIOR TO PERFORMING ANY MAINTENANCE OR REP
3. NO POWER DRIVE IS TO BE USED IN A CORROSIVE OR EXPOLSIVE
ENVIRONMENT.
4. NEVER OBSCURE THE WARNING LABELS ON YOUR UNIT.
5. DO NOT OPERATE THE POWER DRIVE WHEN UNDER THE INFLUENCE OF
DRUGS, ALCOHOL OR MEDICATION.
6. POWER DRIVES ARE INHERENTLY SELF-LOCKING, MEANING THAT UNDER
MOST CIRCUMSTANCES A TORQUE OF LESS THAN 3000 in-lb APPLIED TO
THE OUTPUT SHAFT WILL NOT CAUSE THE SHAFT TO ROTATE. HOWEVER, VIBRATION OR ROTATION OF THE INPUT SHAFT COULD CAUSE THE
BOX TO LOSE ITS ABILITY TO RESIST THIS TORQUE, RESULTING IN A RUNAWAY CONDITION. FOR THIS REASON, POWER DRIVES SHOULD NOT
BE USED AS A BRAKE IN APPLICATIONS WHERE PERSONAL INJURY
OR PROPER
CONDITION.
7. DO NOT MACHINE OR WELD ANY PAR
AL
TERATIONS MAY WEAKEN THE STRUCTURAL INTEGRITY OF THE UNIT
AND WILL VOID YOUR WARRANTY.
TY DAMAGE COULD RESULT FROM A RUN-AWAY
AIR.
T OF THE POWER DRIVE. SUCH
I N S TA L L AT I O N
MOUNTING
Three 5/16" UNC x 1/2" deep mounting points are provided on the main
output side of the gearbox in order to facilitate bulkhead mounting. The
bulkhead should be drilled in accordance with the dimensions in Figure 3.
Because of the torque involved, it is important that the mountings are
secure, it is recommended that the mounting bolts be of Grade 5 or higher
and torqued to 65-75 in-lb.
All three mounting holes must be used. Use only the threaded holes provided,
do not drill and tap new hole(s). Do not weld the gearbox or any parts of the
unit.
5
P E R F O R MAN C EI N S TA L L AT I O N (CO N T. )
Figure 3: Mount Hole Locations (Inches)
1.03
2.50
1.03
1.03
1 HOLE 7/8
COUPLING
Your Power Drive has an output shaft for coupling to a load.
Figure 2 on page 3 shows the specifications on the shaft configuration.
Care should be taken to ensure that any tube that is rigidly attached to the
gearbox is as straight as possible to remove the possibility of an oscillating
load.
OVERHUNG LOAD
The table below shows the maximum allowable overhung loads that may be
applied to either output shaft at a distance P
seal face to the location of the load (see Figure 2).
P (in) Max. Overhung Load (Lbs.) P (in) Max. Overhung Load (Lbs.)
0.75 900 3.75 270
1.75 504 4.75 216
SPLASH COVER
A Splash Cover and 2 mounting screws are provided with each unit. If you
have a manual override unit, remove the round black plastic cover from the
gearbox (Figure 1) and install it into the access hole in the splash cover.
Once the gearbox installation is complete, place the splash cover over the
unit and install the two self-tapping screws into the gearbox housing.
3 HOLES 3/8
. P is measured from the oil
E L E C T R I C A L CONNECTI O N – D C U N I T S
This section applies to the electrical connections of the DC Power
Drives only.
Caution: When attaching wires to the motor terminals, hold the inner
nut when tightening the outer nut. Do not allow terminals to rotate causing internal wire breakage.
Caution: Leave all cable connections to the battery terminals unconnected until all wiring has been installed and checked thoroughly for correct connections. All wiring should be bound and securely fastened to the
adjacent structure using cable ties where necessary
.
This unit operates on standard automotive direct current. Proper wire size
and length are critical for the unit to perform properly. See the
Performance section for further information.
6
E L E C T R I C A L CON N E C T I O N – D C U N I T S, (.CONT.)
This section applies to the electrical connections of the DC Power
Drives only.
CONNECTIONS
Electrical connection is made via the two 1/4-20 UNC studs on the end of the
motor (see Figure 2 on page 3). Hold the inner nut with a wrench when
tightening the outer nut. Torgue the outer nut to 21-26 lb. in.
Step (1) Disconnect the battery "negative" terminal connection.
Step (2) Check motor terminals against Figure 2 for identification.
Step (3) Connect stud 1 to the positive terminal and stud 2 to the negative
terminal. This will cause the gearbox output shaft to rotate in a clockwise
direction as viewed from the mounting side. Reversing the connections will
reverse the direction of rotation.
7
P O W E R D R I V E A S S E M B LY
8
9
10
2
1
Figure 6: Power Drive Assembly
⁄
8
R E P L A C E M E N T PA R T S
1 1 12V Motor (Power Drive #'s 719527 90-33319
1 1 12V Motor (Power Drive #'s 719627 90-33295
1 1 24V Motor (Power Drive #'s 719537 90-33320
1 1 24V Motor (Power Drive #’s 719637 90-33318
1 1 12V Motor (Power Drive #’s 716727 90-33294
2 2 Flanged Nuts, 1/4 -20 90-23149-02
8 1 Splash Cover (Power Drive #'s 60-33291-01
) )
716527
716627)
716537)
719630, 719632)
719727)
719537,
716537)
8 1 Splash Cover (Power Drive # 60-33302-01
719630
8 1 Splash Cover with Screws 61-17315
(Power Drive #'s 716527,
716627, 716727, 719527, 719621,
719627, 719631, 719637, 719727)
9 2 Self-tapping Cover Screw 60-23039-12
10 3 5/16 UNC Grade 5 or Better
Mounting Bolts and Washers
Not Supplied
M A I N T E N A N C E A N D R E PA I R
Periodically check the 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 your warranty.
LUBRICATION
The gearbox is lubricated and sealed for life. If re-lubrication is necessary
(following repair or disassembly), the gearbox should be filled with 5 ounces
of Mobil SHC 630 lubricant or equivalent.
9
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