OWNER’S MANUAL
INSTALLATION • OPERATION • MAINTENANCE
SAFETY PRECAUTIONS • REPAIR PARTS
READ AND UNDERSTAND THIS MANUAL
BEFORE INSTALLATION AND OPERATION
OF YOUR SUPERWINCH PRODUCT.
90-10439 Rev D– 5/15/98
Superwinch, Inc. Superwinch, Ltd.
Winch Drive Abbey Rise, Whitchurch Road
Putnam, CT 06260 Tavistock, Devon PL 19 9DR
U.S.A. England
Tel. (860) 928-7787 Tel. (1822) 614101
Fax (860) 928-1143 Fax (1822) 615204
MODEL EX1
12 V olt DC Electric Winch
Part No. 1110
2
Thank you very much for purchasing a Superwinch product. We hope and
expect that you will be pleased with the performance and reliability of this
unit. If you are not, for any reason, please contact our Customer Service
Department: (860) 928-7787 USA; (1822) 614101 England.
When requesting information or ordering replacement parts; always give the
following information:
1. Winch Part Number (1110)
2. Part Number (found in Replacement Parts List section)
3. Part Description
It is extremely important that you read and understand this Owner’s Manual
prior to installing and using your winch. Pay particular attention to “General
Safety Information” and be sure that anyone else who might use your winch
also studies this section.
Pay particular attention to the caution notes preceded
with this symbol. The notes contain advice for your
protection.
Description Quantity
Winch assembly with wire rope and hook 1
Switch and harness assembly with two 5' long 10-gauge wires 1
Handsaver 1
Circuit breaker assembly 1
3/8 x 1-1/2 grade 5 bolts, nuts, flat washers and lock washers 2 ea.
Cable ties 5
INTRODUCTION
UNPACKING : This carton contains the following items. Please unpack carefully. Read instructions before beginning.
PERFORMANCE
Motor
Load Speed Curr ent
lbs kg ft/min m/min Amps
0 0 20 6.1 20
1,000 454 12 3.66 90
Working Load . . . . . 1,000 lbs. (454 kg)
Stall Load . . . . . . . . . 1,350 lbs. (612 kg)
Wire Rope . . . . . . . . . . 5/32 x 25 ft.
Voltage . . . . . . . . . . . . . 12 Volt DC
Motor . . . . . . . . . . . . . . . . . . .6 hp
Gear Ratio . . . . . . . . . . . . . . . 123:1
Weight . . . . . . . . . . 15 lbs. (6.8 kg)
SPECIFICATIONS
Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º)
Lbs.**
kg**
5,000
2268
3,400
1542
2,600
1179
1,200
544
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 (see Figure 1). Double-line operation with optional
pulley block (p/n 2227) approximately doubles capacity of winch (see Figure 1).
LOAD CAPACITY**
Your new Superwinch is a powerful
machine. Treat it with respect, use it
with caution and always follow
these safety guidelines.
1. The EX1 winch is rated at 1,000
lbs. (single-line) capacity. DO NOT
OVERLOAD. DO NOT ATTEMPT
PROLONGED PULLS AT HEAVY
LOADS. 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
HEAVY LOADS, WE RECOMMEND THE USE OF THE
OPTIONAL PULLEY BLOCK AND
HOOK ASSEMBLY (PART NO.
2227) TO DOUBLE-LINE THE
WIRE ROPE (Figure 1). This
reduces the load on the winch
and the strain on the wire rope
by approximately 50%.
2. AFTER READING AND UNDER-
STANDING THIS MANUAL,
LEARN TO USE YOUR WINCH.
Practice using it so you will be
familiar with it when the need
arises. Periodically check the
winch installation to assure that
all bolts are tight.
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. Do not step over a taut
wire rope or allow anyone else to
do so. Do not stand between the
winch and load.
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). Never
replace the wire rope with any
kind of rope other than the type
and size specified in the Wire
Rope section of this manual.
6. USE HEAVY LEATHER GLOVES
when handling wire rope. DO
NOT LET WIRE ROPE SLIDE
THROUGH YOUR HANDS. A bro-
ken strand could seriously injure
your hands.
7. KEEP CLEAR OF THE WINCH,
WIRE ROPE, AND HOOK WHEN
OPERATING WINCH. NEVER put
your fingers through the hook
when reeling in the last few feet
of line. If your finger should
become trapped in the hook, you
could lose your finger. Use the
HAND SAVER BAR (Figure 2) to
guide the hook within the last
few feet. Never guide a wire rope
on or off the drum with your hand.
3
GENERAL SAFETY
INFORMATION
Figure 2
Single Line
Double Line
Figure 1
4
8. NEVER HOOK THE WIRE ROPE
BACK ONTO ITSELF. Use a nylon
sling (Superwinch Part No. 1509).
Hooking the wire rope onto itself
can damage the rope (Figure 3).
9. It is a good idea to lay a heavy
blanket or jacket over the wire
rope near the hook end when
pulling heavy loads (Figure 4). If
a wire rope failure should occur,
the cloth will act as a damper
and help prevent the rope from
whipping. Raise the hood of the
vehicle for added safety.
10.NEVER USE YOUR WINCH FOR
LIFTING OR MOVING PEOPLE.
The winch is not designed nor
intended for use in lifting or
moving people.
11.Your winch is not designed or
intended for overhead hoisting
operations.
12.DO NOT ATTEMPT PULLS
FROM ANGLES WITHOUT
USING OPTIONAL FAIRLEAD,
P/N 1507 OR 1560, as damage
to winch and wire rope may result.
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.
14.Always operate winch with an
unobstructed view of the winching operation.
15.IT IS RECOMMENDED THAT A
FAIRLEAD BE USED to guide
the wire rope onto the winch.
Two types of fairleads are
offered: the Hawse Fairlead,
Part No. 1507, and the Roller
Fairlead, Part No. 1560.
16.DO NOT OPERATE WINCH
WHEN UNDER THE INFLUENCE
OF DRUGS, ALCOHOL OR
MEDICATION.
17.ALWAYS REMOVE THE
SWITCH BEFORE WORKING IN
OR AROUND THE WIRE ROPE,
FAIRLEAD, OR WINCH DRUM
(THE DANGER ZONE) so that
the winch cannot be turned on
accidentally.
18.NEVER WORK ON OR
AROUND THE FAIRLEAD OR
WINCH DRUM, WHEN WINCH
IS UNDER LOAD.
19.When using your winch to move
a load, place the vehicle transmission in neutral, set vehicle
parking brake, chock all wheels,
and keep the engine running.
GENERAL SAFETY
INFORMATION
(CONT.)
Wrong Right
Right
Wrong
Figure 5
Figure 3
Figure 4
20.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 down straps. Contact your
local Superwinch dealer.
21.USE ONLY FACTORY
APPROVED SWITCHES,
REMOTE CONTROLS, AND
ACCESSORIES. Use of non-fac-
tory approved components may
cause injury or property damage
and could void your warranty.
22.DO NOT MACHINE OR WELD
ANY PART OF THE WINCH.
Such alterations may weaken
the structural integrity of the
winch and could void your warranty.
23.Maintain 5 turns of wire rope
around wire rope drum to prevent the wire rope from pulling
off under load.
24.NEVER INSTALL WINCH IN
SUCH A WAY THAT THE
WARNING AND INSTRUCTION
LABELS ARE OBSCURED.
Someone who had not read this
manual may need to see them
to understand the proper operation of the winch. ALWAYS
CHECK FOR CORRECT DIRECTION OF ROTATION BEFORE
USING WINCH. The winch must
be properly wired to ensure correct direction of rotation.
25.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.
26.Always install winch in such a
way that the operator will be
standing with a comfortable
posture, with unobstructed
access to, and a clear view of the
winch, its labels, and its controls.
TOOLS NEEDED FOR MOUNTING
AND WIRING
Open End Wrenches – 9/16", (2), or
small adjustable wrenches, wire
strippers, or cutters, terminal
crimpers (pliers), torque wrench, Pair
3/8" bolts and nuts, four flat and
two lock washers.
MOUNTING
The mounting location for the
winch must be capable of handling
the loads of the job you intend the
winch to do. Suggested locations
are: a flat front or rear bumper of a
vehicle, on a pickup truck bed or the
winch stand on a trailer.
The winch can be mounted in a horizontal or vertical position (Figure
6). Do not mount the winch where
there would be the possibility of it being submerged in water.
The winch is weather resistant but
not waterproof.
Superwinch mounting (fitting) kits
are available for most popular vehicles. If you can’t obtain a kit locally,
contact Superwinch at the address
listed in this manual for the name of
a Superwinch dealer near you.
5
GENERAL SAFETY
INFORMATION
(CONT.)
INSTALLATION
Horizontal
Vertical
Figure 6
6
MOUNTING (CONT.)
Drill two 7/16" (12mm) diameter
holes with center lines exactly
3-11/16" (93.66mm) apart (Figure 7)
in the support chosen for the
winch. Attach the winch to the support with two (2) 3/8-16 Hex Head
Bolts. Be sure the hardware is
assembled as shown. Tighten the
hardware to 35 lb. ft. torque.
ELECTRICAL INSTALLATION
This winch operates on standard
automotive 12-volt Direct Current.
Do not
connect winch
to 110 Volt house current. Motor
damage or fatal shock may occur.
Automobile
batteries contain gasses which are flammable and
explosive. Wear eye protection during installation and remove all metal
jewelry. Do not lean over the battery while making connections.
The red wire from the switch is
connected to the circuit protector
terminal using the hardware provided. The other end of the circuit
protector is connected to the battery positive terminal. The black
wire from the switch is connected
to the battery negative terminal
(Figure 8). Be sure connections are
clean and tight. Do not connect the
switch or wiring to any other power
source in the vehicle.
Starting at the winch, feed the
wires into the engine compartment.
If possible, use the routing and support for the existing wiring.
If it is necessary to drill holes, to
feed the wires, be sure the wires
are protected from damage by
using a grommet (Figure 9). Use
cable ties to secure wires along the
route.
When you make the ground connection, be sure to scrape off any
dirt from the bolt that would prevent a good connection.
Note: If the winch is mounted at
the rear of the vehicle, a special
wiring kit (P/N 1520) is available
from Superwinch.
When extending the lead wires for
rear vehicle mount, always use 8
gauge wire or heavier to extend the
existing wires to the battery.
Figure 7
Bolt
Flat Washer
Support
Flat Washer
Lock Washer
Nut
Figure 8
Circuit
Protector
Chassis
Ground
Red
Black
Figure 9
Grommet
Tie Strap
Be Prepared
7
If connection to the battery positive
terminal is not possible because of
the terminal design, connect the
circuit protector to the starter
solenoid “hot” side. Determine the
“hot” side by tracing the battery
cable to the solenoid connection.
Connect the red supply wire to the
same terminal to which the battery
cable is connected (Figure 10).
Note: Special adapters are available
from your local Auto Parts Dealers
for making connections to Side Post
Batteries.
The switch and motor end are
designed so the switch will mount
properly only when installed as
shown in Figure 11. Do not attempt
to install the switch in the opposite
direction. If the switch is installed
incorrectly and electrical contact
made, the winch will run in a direction opposite that is indicated on
the product label resulting in possible operator injury.
Secure the switch to the motor by
tightening the round thumb screw
on the outside of the switch (Figure
12). The screw threads into the
tapped hole between the brass
motor contact (Figure 11). Do not
use pliers or over-tighten the thumb
screw.
After the switch is in place, remove
excess slack from the wiring harness
in the vehicle by doubling over
slack areas and tying securely. Do
not leave any dangling or loose
wiring.
Circuit
Protector
From Switch
Figure 10
Battery
Cable
Circuit
Protector
Red
Solenoid
Figure 11
Switch
Wires
Figure 12
8
SWITCH OPERATION
When the switch springs back to the
“OFF” position, an electrical shunt provides dynamic braking action which
prevents the winch from coasting
(Figure 13). THIS BRAKING ACTION IS
NOT A LOAD HOLDING DEVICE.
When the switch is centered in the
“OFF” position, the shunt reduces the
action of a load backdriving the winch.
However, a load can cause the winch
to creep. With the switch removed
from the winch, there is a greater tendency for a load to backdrive the
winch.
The winch is
not designed
as a load holding device.
The switch should be removed from
the winch when unattended to prevent unauthorized operation. A
Quickconnect (Superwinch P/N 1551) is
also available as an accessory to disarm
the winch. Because the winch will not
hold a load, in trailing or load holding
applications, tie down ropes or straps
must be used to secure loads.
Remote operation of the switch
(Figure 14) can be achieved by tying
one end of a cord through each “ear”
of the switch.
Periodically check tightness of the
mounting bolts and electrical connections. Remove any dirt or corrosion
that may have accumulated on the
electrical connections.
LUBRICATION
Your new winch has lifetime lubrication. There will be some grease leaking
out of the winch, especially during the
first few operations. This is normal and
it is not necessary to grease or oil any
part of the winch at any time.
WIRE ROPE
A part of your winch that will require
periodic attention and eventual
replacement is the wire rope. Inspect
the wire rope for wear frequently. If
fraying exists, replace the wire rope at
once. Your winch uses 5/32" diameter
galvanized aircraft type 7 x 19 wire
rope that is 25 feet long (2,800 lb.
breaking strength). Always replace the
wire rope with Superwinch replacement wire rope, P/N 1535 (see
Replacement Parts List).
OPERATION
Figure 13
Off
Rope In
Rope Out
MAINTENANCE
Figure 14
9
If the winch motor labors and then
stops, the load is too great.
Evidence of this will be a motor
almost too hot to touch. Repeated
occurrence of this condition indicates that the load exerted on your
winch is beyond its capacity and
may burn out the winch motor. Use
of the accessory pulley block, P/N
2227, will increase the winch‘s
capacity.
MOTOR DOES NOT OPERATE
Follow these steps in order. Make
sure your vehicle engine is running
and then try operating your winch
after each step.
1. Remove switch, then replace it on
the motor, making certain that it
is aligned properly over brass
motor connectors and that thumb
screw is snug.
2. If motor does not operate, check
all electrical connections on battery and ground, making sure
that they are clean and tight.
3. Check the wiring harness to
determine if all insulation is
intact. Damaged insulation could
cause a short circuit.
TIPS F0R EXTENDING THE LIFE OF
YOUR WINCH
1. KEEP A TIGHTLY AND EVENLY
WOUND WIRE ROPE DRUM. Do
not allow the wire rope to
become loosely wound. A looselywound 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 at all
times. During winching, periodically check to see that the wire
rope is winding on evenly. 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 small hill or
incline and winch your vehicle up
the incline.
2. DO NOT ALLOW MOTOR TO
OVERHEAT. Remember, the
winch is only for intermittent use.
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. If the motor is uncomfortably warm, allow the motor
to cool before continuing. Keep
the engine running to recharge
the battery during this break.
3. USE A PULLEY BLOCK FOR
HEAVY LOADS. To maximize
winch and wire rope life, use a
pulley block, P/N 2227, to doubleline heavier loads.
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 A PULL.
TROUBLE SHOOTING
Figure 15
10
5. PREVENT KINKS BEFORE THEY
OCCUR.
6. EQUIPPING THE WINCH WITH A
ROLLER FAIRLEAD, P/N 1560,
Figure 17, will substantially
reduce wear on the wire rope
during angle pulls. The rollers
eliminate heavy rubbing and
abrasion to the wire rope.
a
b
c
a.This is the start of a kink. At this time,
the wire rope should be straightened.
b. The wire rope was pulled and loop has
tightened into a kink. Wire rope is now
permanently damaged and must be
replaced.
c. The result of kinking is that each
strand pulls a different amount causing
strands under greatest tension to break
and reduce load capacity of the wire
rope. The wire rope must be replaced.
Figure 17
Figure 16
10
11
REPLACEMENT
PARTS LIST
1
18
16
2
3
6
545
7
8
9
11
12
13
14
15
10
1 Handsaver 89-32300 1
2 Rotating Gear Drum 90-32038 1
3 Perimeter Bearing 90-23137 1
4 Nylon Step Washer 90-12418 1
5 Carrier Bearing 90-23140 2
6 Planetary Gearing Assembly 90-23138 1
7 10-Tooth Sun Gear 90-22865 1
8 Flat Thrust Washer 90-23120-08 1
9 Stationary Ring Gear w/ Needle Bearing 90-12454 1
10 12 Volt Motor w/ Ring Gear
& Needle Bearing Primed 90-32084 1
11 Shim Washer 90-23120-05 AR
12 Bushing 90-12174 1
13 5/16" Socket Head Cap Screw 90-23056-02 2
14 Main Frame Base Plate 90-41019 1
15 Repair Switch Assembly w/ two 3 ft. leads (includes
two butt splices for connecting to old harness) 1519 1
16 5/32" x 25' Wire Rope & Hook Assembly 1535 1
17 12V Circuit Breaker Assembly (Not Shown) 90-22873-03 1
18 Rope Retainer 90-12419 1
19 7,000 lb. Pulley Block (Figure 15) 2227 —
20 Hawse Fairlead (Not Shown) 1507 —
21 Roller Fairlead (Figure 17) 1560 —
22 Quickconnect (Not Shown) 1551 —
AR denotes “As Required”
Reference
Number Description Part Number Qty
NOTES
12
NOTES
13
14
NOTES
15
WARRANTY REPAIR CENTERS
USA
Superwinch Inc.
Winch Drive
Putnam, CT 06260
860-928-7787
repair@superwinch.com
C & A Equipment
W. 6209 Hwy. 33
P.O. Box 387
Pardeeville, WI 53954
608-429-9353
Electric Motor Repair
2010 North 4th Street
Minneapolis, MN 55411
612-588-4693
Marine Electric
9804 James Circle
Bloomington, MN 55431
612-881-0077
Appliance Hospital
4530 Beechnut
Houston, TX 77096
713-668-6705
J & L Equipment
12346 S.E. Raymond
Portland, OR 97236
503-760-6117
Zorko’s Alternator Service
30 Wells Road
Home, PA 15747
800-468-5055
Electric Motors of Iowa
50 Commercial Court
Iowa City, IA 52246
319-354-4040
CANADA
Les Equipment Twin
10401 Parkway Blvd.
Ville D’Anjou, Quebec H1J 1R4
514-353-1190
DJT Automotive
105 Riviera Drive, Unit 11
Markham, Ontario L3R 5M1
416-496-0631
Buffalo Industries
251 Princess Street
Winnipeg, Manitoba R3B 1M1
204-942-1951
Saskatoon All Terrain
421 Dickey Cresent Road
Saskatoon, Saskatchewan S7L 5P2
306-394-2155
Air Electric Service
6739 76th Avenue
Edmonton, Alberta T6B 0A9
403-465-0906
H.E. Brown Supply co., Inc.
150 MacIntyre Street East
P.O. Box 538
North Bay, Ontario P1B 8J3
705-472-0400
Argo Dist.
9431 63rd Avenue
Edmonton, Alberta T6B OG2
403-438-4443
UNITED KINGDOM
Superwinch, LTD
Abbey Rise, Whitchurch road
Tavistock, Devon PL19 9DR
(1822) 614101
WORLDWIDE
Contact your local Superwinch
Distributor or call Superwinch
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