Superwinch LT2000 ATV User Manual [en, es, fr]

OWNER’S GUIDE

LT2000 2000 LB 907 kg

12 Volt DC Electric Winch

READ AND UNDERSTAND THIS GUIDE BEFORE

INSTALLATION AND OPERATION.

87-10991 Rev - 8/3/07

Superwinch, Inc.
Winch Drive
Putnam, CT 06260
U.S.A.
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
www.superwinch.com

Superwinch, Inc.

Unit D, Union Mine Road

Pitts Cleave Ind Est

Tavistock, Devon

PL19 OPW England
Tel: [phone]
Fax: [phone]

e-mail: [e-mail]

www.superwinch.com

Throughout this manual, you will find notations with the following headings:

Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.

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.

The following symbols on the product and in the Owner's manual are used:

Note: Indicates additional information in the installation and operation procedures of your winch.

Correct installation of your winch is a requirement for proper operation.
Please Note: Winch is designed primarily for intermittent applications. This winch is not designed to
be used in industrial or hoisting applications and Superwinch does not warrant it to be suitable for
such use.

Read Owner's
Manual

Always Use
Handsaver

Keep clear of winch,
wire rope and hook
while operating

Never use winch
to lift or move
people

Never use
winch to hold
loads in place

CAUTION

!

1

DANGER

!

WARNING

!

CAUTION

!

Your winch is a very powerful
machine. If used unsafely or
improperly, there is a possibility
that property damage or personal
injury could result.

The responsibility

for safe installa­tion 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.

The wire rope

may break before
the winch stalls. For heavy loads, use
a pulley block to reduce the load on
the wire rope.

1. Maximum working load capacity

is on the wire rope layer closest
to the drum. DO NOT OVER­LOAD. DO NOT ATTEMPT PRO­LONGED PULLS AT HEAVY
LOADS. Overloads can damage
the winch and/or the wire rope
and create unsafe operating con­ditions. FOR LOADS OVER 1,000
POUNDS (454 kg), WE RECOM­MEND THE USE OF THE OPTION­AL PULLEY BLOCK TO DOUBLE
LINE THE WIRE ROPE (Figure2).
This reduces the load on the
winch and the strain on the wire
rope by approximately 50%.
Attach hook to load bearing part.

The vehicle engine should be
running during winch opera­tion. If considerable winching is

performed with the engine off,
the battery may be too weak to
restart the engine.

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 the
load. The combination of the
winch and vehicle pulling togeth­er could overload the wire rope
and the winch.

4. 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.

7. NEVER WINCH WITH LESS THAN 5
TURNS of wire rope AROUND THE
WINCH DRUM since the wire rope
end fastener may NOT withstand
full load.

WARNING

!

WARNING

!

GENERAL SAFETY

INFORMATION

Figure 2

Double Line

Single Line

2

3

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
lose your finger.
ALWAYS USE THE
HANDSAVER when guiding the
wire rope in or out (See Figure

3).

9. NEVER HOOK THE WIRE ROPE
BACK ONTO ITSELF because you
could damage the wire rope.
Use a nylon sling (Figure 4).

10. 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 5). If
a wire rope failure should occur,
the cloth will act as a damper
and help prevent the rope from
whipping.

11. NEVER USE YOUR
WINCH FOR LIFTING OR
MOVING PEOPLE.

12. Your winch is not intended for
overhead hoisting operations.

13. AVOID CONTINUOUS PULLS
FROM EXTREME ANGLES as this
will cause the wire rope to pile
up on one end of the drum
(Figure 6). This can jam the wire
rope in the winch, causing dam­age to the rope or the winch.

14. NEVER OBSCURE THE WARNING
INSTRUCTION LABELS.

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. NEVER WORK ON OR AROUND
THE WINCH DRUM WHEN
WINCH IS UNDER LOAD.

19. DO NOT OPERATE WINCH
WHEN UNDER THE INFLUENCE
OF DRUGS, ALCOHOL OR
MEDICATION.

Wrong Right

Figure 4

Figure 5

Figure 3

Figure 6

Right

Wrong

Use the supplied hardware and
Brackets to mount the handlebar
Switch. Mount the solenoid close to
the battery, in the storage box, under
the seat or on the frame.

The location of

the Switch MUST
not interfere with safe operation of
the vehicle. Wiring MUST NOT come
in contact with any moving parts or
sharp edges, such as engine, sus­pension, brakes, exaust, or steering.

Route the red wire from the handle­bar Switch to the ignition switch
and connect to the wire that is
powered when ignition is in the ON
position ONLY.

Route the two wires from the sole­noid to the motor. Route the two
wires from the solenoid to the bat­tery. Attach the circuit breaker to the
end of the red wire. Wrap the circuit
breaker with electrical tape to pre­vent accidental short circuits.

Apply several layers of electrical
tape where wiring may come into
contact with sharp metal parts of
the vehicle to prevent insulation
abrasion or cutting.

Attach the short circuit breaker wire
to the battery positive terminal and

reattach the terminal to the battery.
Connect the remaining black sole­noid wire to the battery negative ter­minal and connect the terminal to
the battery.

Step (5)

Pull and turn (see Figure 8) the
freespool clutch knob to the “Free”
position. Pull several feet of wire
rope off the drum. Return the clutch
knob back to the “Engaged” posi­tion. Activate the winch in Cable Out
momentarily to check drum rotation
direction. If the drum rotates in the
wrong direction, recheck your wiring.

FREESPOOL OPERATION

Pull and turn the clutch knob to the
“Free ” position as shown in Figure

8. If there is a load on the wire rope,
the clutch knob may not pull out
easily. DO NOT FORCE THE CLUTCH
KNOB. Release tension on the clutch
by jogging out some of the wire
rope. Release the clutch and 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
returning the clutch knob to the
“Engaged” position. (See Figure 8).

4

5

20. ALWAYS DISCONNECT WINCH
POWER LEADS TO BATTERY
BEFORE WORKING IN OR
AROUND THE WINCH DRUM 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.

22. When using your winch to move
a load, place the vehicle trans­mission in neutral, set vehicle
brake, and chock all wheels.

23. DO NOT USE THE WINCH TO
HOLD LOADS IN PLACE.
Use other means of
securing loads such
as tie down straps.

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 could void your warranty.

26. DO NOT CONNECT WINCH TO
EITHER 110V 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. Use caution when pulling or
lowering a load up and down a
ramp or incline. Keep people,
pets and property clear of the
path of the load.

Correct installation of your winch is
required for proper operation.

This winch MUST

be mounted
with the wire rope in the under­wind direction. Improper mounting
could damage your winch and void
your warranty.

Step (1)

Install mounting kit or structural
support for winch.

Step (2)

Mount the winch to the mounting
kit base plate or to the mount that
you have designed. Typical mount is
to a flat surface capable of han­dling the loads.

The M8 x 1.25 x 30mm mounting
bolts supplied are the correct length
for use with a 1/4" (6.3mm) thick
mounting plate.

Do not

substitute
any strength grade weaker than
ISO grade 4.6

Step (3)

Disconnect the vehicle battery leads.

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.

Step (4)

Refer to Figure 7 for wiring
diagram.

WARNING

!

WARNING

!

WARNING

!

WARNING

!

INSTALLATION

Circuit

Breaker

(with - .25m

Red Wire)

Short

RED

(.5 m)

Short

Black

(.5 m)

Long
BLACK
(1.8 m)

Long

RED

(1.8 m)

Red

Terminal

White

Terminal

Solenoid

Battery (12V DC)

BLACK

GREEN

Rocker Switch

RED

+ Ignition Switch

Figure 7