Superwinch LT3000 ATV User Manual [en, es, fr]

OWNER’S GUIDE

LT3000 ATV 3000 Ib (1361 kg)

! CAUTION

12 Volt DC Electric Winch

READ AND UNDERSTAND THIS GUIDE BEFORE

INSTALLATION AND OPERATION.

Superwinch, LLC.		Superwinch, Inc.
Winch Drive	Union Mine Road
Putnam, CT 06260		Pitts Cleave
U.S.A.	Tavistock, Devon
Tel: [phone]		PL19 OPW UK
Fax: [phone]	Tel: 44	(0) 1822 614101
e-mail: [e-mail]	Fax: 44	(0) 1822 615204
www.superwinch.com	e-mail: [e-mail]
	www.superwinch.com

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

! DANGER

!WARNING

!CAUTION

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:

Read Owner's	Always Use	Keep clear of winch,	Never use winch	Never use
Manual	Handsaver	wire rope and hook	to lift or move	winch to hold
		while operating	people	loads in place

Note: Indicates additional informationin the installationand operation procedures of your winch.

Correct installationof your winch is a requirement for proper operation.

Please Note: Winch is designed primarily for intermittentapplications.This winch is not designed to be used in industrial or hoisting applicationsand Superwinch does not warrant it to be suitable for such use.

87-10994 Rev - 3/1/10

1

GENERAL SAFETY

INFORMATION

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 ! WARNING for safe installa-

tion 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.

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.

Single Line

Double Line

Figure 2

2.AFTER READING AND UNDERSTANDING THIS MANUAL, LEARN TO USE YOUR WINCH.

After installingthe 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.

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) .

Figure 3

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

Wrong

Right

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.

Figure 5

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.

Figure 6

Wrong Right

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.

2

3

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.

4

INSTALLATION

Correct installation of your winch is required for proper operation.

Step (1)

Disconnect the vehicle battery leads from the battery.

Step (2)

Secure winch (Figure) to mounting plate or structural support using the M8 x 1.25 x 30mm mount bolts, flat washers, and lock washers provided. Typical mount is to a flat secure surface capable of handling the required loads.

Step (3)

Remove bottom roller from the roller fairlead. Turn the freespool knob to disengage and pull a few inches of wire rope from the drum. Pass the wire end under the remaining roller, and then replace the bottom roller. Next secure the roller fairlead

( Figure 7) to the mounting roller plate or structural support using the M8 x 1.25 x 20mm bolts, flat washers, and lock washers provided.

Do not substitute ! WARNING any strength grade

weaker than ISO grade 8.8

Be sure that both

! WARNING the mounting plate and winch hardware have been properly tightened.

		No part of the vehicle
	! CAUTION
		(skid plates, wiring,
auxiliary lights, tires, ect.) should

impede the operation of your Superwinch®. When mounting, check all vehicle and winch parts for free operation. Be sure that the winch mounting location does not significantly reduce ground clearance.

! WARNING This winch MUST be mounted with the

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

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 frame.

			The location
	!	WARNING
			of the switch
	MUST not interfere with safe
	operation of the vehicle.
	Wiring MUST NOT come in			Figure 7
	contact with any moving
	parts or sharp edges, such
	as engine, suspension, brakes,
	exhaust, 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 Figure 8. Route				winch in Cable Out momentarily to
	the two wires from the solenoid to				check drum rotation direction. If the
	the battery. Attach the circuit breaker				drum rotates in the wrong direc-
	to the end of the red wire. Wrap the				tion, recheck your wiring.
	circuit breaker with electrical tape to				FREESPOOL OPERATION
	prevent accidental short circuits.
	Apply several layers of electrical tape				Turn the clutch knob to the, Disen-
	where wiring may come into contact				gaged “Free” position as shown in
	with sharp metal parts of the vehicle				Figure 10. If there is a load on the
	to prevent insulation abrasion or cut-				wire rope, the clutch knob may not
	ting.				pull out easily. DO NOT FORCE THE
	Attach the short circuit breaker wire to				CLUTCH KNOB. Release tension on
					the clutch by jogging out some of
	the battery positive terminal and reat-
					the wire rope.
	tach the terminal to the battery. Con-
					Release the clutch and pull out the
	nect the remaining black solenoid wire
					wire rope and secure to anchor or
	to the battery negative terminal and
					load. Check that there are at least
	connect the terminal to the battery.
					five (5) turns of wire rope left on
	STEP (4)				the drum. Re-engage the drum by
	Turn the clutch knob to, Disengaged				returning the clutch knob to the,
	“Free” position as shown in Figure 10.				“Engaged” position. (See Figure 10).

Pull several feet of wire rope off the drum. Return the clutch knob back to the, “Engaged” position. Activate the

5

4

Figure 8
Figure 6			21
		Red
		Y llow – 6 ga.
ATV MASTER WIRINGS
	ATV main
	switch
	Fuse	Black	Blackk
		Green
Brown/Blue		Red	Green
		BlueBlack
	Red
	ATV wiring
optional remote	connection		Green
control			Black
		optional

WINCH

12

BlueBlack– 6 ga.- 6 ga.

	BATTERY
	Black – 6 ga.
	CIRCUIT
SOLENOID	BREAKER
	"+"
	to solenoid
	Red – 6 ga.
	to circuit breaker

9

Ø.86”

Ø 21.8mm

REMOTE SOCKET MOUNTING

1. Detemine the mounting location for the remote socket.

2.Drill three holes using the included dimensions as a guide.

3.Once the remote socket is mounted, route the jacketed green and black leads back to where the solenoid is mounted. Splice the red lead to a key controlled electrical wire on the ATV.

1.95”

49.5mm

.18” 4.6mm

.98”

24.8mm

Disengaged

(Freespool)

			Clutch must be fully
	!	CAUTION
			engaged before
winching. Never engage clutch knob
while drum is turning.
		Figure 10

Engaged

6

			If the winch motor
	!	CAUTION
			stalls, do not
continue to apply power.

INTERMITTENT DUTY

An electric winch is like any other motor driven power tool such as an electric drill or saw. The electric motorshould not be allowed to become excessively hot. Normal precautions will extend the life of your motor. Keep the durations 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.

For further information and complete warranty, visit our website. www.superwinch.com

REPLACEMENT PARTS LIST

	1	5
8	7
		6
2		4
	3
	9
Reference No.	Description	Part Number
1	Wire Rope Assy.	1511F
2	Motor Assy.	87-12890
3	Drum Assy.	87-12891
4	Gearbox Assy.	87-12892
5	Solenoid Assy.	87-12893
6	Handlebar Rocker Switch	87-12894
7	Hand Held Remote	87-12895
8	Circuit Breaker Assy.	87-22873-16
9	Clevis Hook Assy.	87-42615
		7