OWNER’S MANUAL
INSTALLATION • OPERATION • MAINTENANCE
SAFETY PRECAUTIONS • REPAIR PARTS
S3000, S4000, S5000
12 & 24 Volt DC Electric Winches
With Remote Control
READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION
AND OPERATION OF YOUR SUPERWINCH PRODUCT.
89-12792 Rev - 1/30/04
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) 963-0811 Fax (1822) 615204
VALABLE A TRAVERS LE MONDE
GARANTIE LIMITÉE. Superwinch, Inc. (le “Vendeur”) garantit à l’acheteur d’origine (“vous”) que
toutes les pièces et composants, à l’exception du câble métallique, sont sans vice de matériaux ou
de fabrication, et ce, pendant une période d’un (1) an à compter de la date d’achat prouvable.
Tout produit Superwinch défectueux sera réparé ou remplacé sans dépenses de votre part si vous
respectez ces procédures. Les garanties énoncées par les présentes sont exclusives tiennent lieu de
toutes autres garanties expresses ou implicites.
PROCÉDURE DE RECOURS À LA GARANTIE LIMITEE.
Dès découverte d’un produit Superwinch défectueux, vous devrez envoyer à Superwinch, à l’usine
ou à un Centre de réparation autorisé par l’usine, une notification écrite dudit défaut et vous
devrez envoyer par courrier ou autre service de livraison le Superwinch défectueux, port et frais
postaux payés à l’avance. Les réparations ou remplacements par le Vendeur conformément à la
présente Garantie s’effectueront normalement dans les quinze (15) jours ouvrables suivant réception du Superwinch défectueux. Le Vendeur ou ses Agents autorisés peut facturer des frais
raisonnables pour les pièces et la main d’oeuvre en cas de réparation non couverte par la présente
Garantie limitée.
LIMITATIONS ET EXCLUSIONS EN CE QUI CONCERNE LA GARANTIE ET LES REMÈDES.
La réparation et/ou le remplacement de tout Superwinch défectueux ou de tout composant d’un
tel Superwinch tel que convenu par les présentes est votre remède exclusif. Les exclusions et limitations de garanties et les limitations de REMEDES ci-dessous seront expressément applicables :
A. Garanties expresses . Le Vendeur garantit que le Superwinch est tel qu’il est décrit dans le
“Mode d’emploi Superwinch” fourni avec la présente; aucune autre garantie expresse n’est donnée en ce qui concerne le Superwinch. Si un modèle ou échantillon vous a été montRé, ledit modèle ou échantillon a été utilisé à des fins d’illustration uniquement et ne sera pas considéré une
garantie que le Superwinch sera conforme au modèle ou à l’échantillon. LE VENDEUR NE DONNE
AUCUNE GARANTIE EXPRESSE EN CE QUI CONCERNE LE CABLE MÉTALLIQUE INCORPORÉ AU PRODUIT.
B. Garantie implicite . LA GARANTIE IMPLICITE DE L’APTITUDE À LA VENTE ET TOUTE AUTRE
GARANTIE IMPLICITE S’APPLIQUERA UNIQUEMENT POUR UNE DURÉE D’UN (1) AN À COMPTER DE
LA DATE D’ACHAT PROUVABLE. LE CABLE MÉTALLIQUE EST VENDU “TEL QUEL” SANS AUTRE
GARANTIE IMPLICITE. CERTAINS ÉTATS AMÉRICAINS NE PERMETTENT PAS DE LIMITER LA DURÉE
DES GARANTIES IMPLICITES; IL EST DONC POSSIBLE QUE LA LIMITATION CI-DESSUS NE S’APPLIQUE
PAS À VOTRE CAS.
C. Dommages indirects. SUJET AUX OBLIGATIONS DE LA GARANTIE LIMITÉE DU VENDEUR
ÉNONCÉES DANS LE PRÉSENT DOCUMENT, LE VENDEUR NE SERA AUCUNEMENT RESPONSABLE DE
DOMMAGES INDIRECTS, DE QUELQUE NATURE QUE CE SOIT, NI DE DOMMAGES INDIRECTS À LA
PROPRIÉTÉ, NI DE PERTES DE PROFITS, NI DE PERTES D’UTILISATION POUVANT SURVENIR À CAUSE
D’UN DÉFAUT, D’UN MAUVAIS FONCTIONNEMENT OU D’UNE PANNE QUELCONQUE DU SUPERWINCH CI-JOINT. CERTAINS ÉTATS AMÉRICAINS NE PERMETTENT PAS D’EXCLURE OU DE LIMITER
LES DOMMAGES INDIRECTS; IL EST DONC POSSIBLE QUE LA LIMITATION CI-DESSUS NE S’APPLIQUE
PAS À VOTRE CAS.
D. Condition de la garantie. Le Vendeur ne sera pas tenu de se conformer aux obligations de
garantie fournies par les présentes si la cause du défaut, du mauvais fonctionnement ou de la
panne du Superwinch est un dommage (ne résultant pas de composants défectueux ou qui fonctionnent mal) ou une utilisation déraisonnable par vous. Le terme Utilisation déraisonnable comprend mais ne est pas limité au manquement à la maintenance, à l’installation et à l’utilisation
raisonnables et nécessaires conformément aux consignes contenues dans le Mode d’emploi
Superwinch, et à l’utilisation du Superwinch pour des charges supérieures à celle figurant dans le
Mode d’emploi pour le modèle en question. La responsabilité du Vendeur sous la présente
garantie ou pour toute perte du produit Superwinch ou dommage à celui-ci ne dépassera pas le
coût de correction des défauts du produit Superwinch ou de remplacement de celui-ci, et lors de
l’expiration de la période de garantie, toute telle responsabilité prendra fin. Les agents, distributeurs et employés du Vendeur ne sont pas autorisés à modifier la présente garantie ni à donner
d’autres garanties complémentaires obligatoires pour le Vendeur. Toute déclaration supplémen-
taire, qu’elle soit écrite ou orale, ne constituera donc pas une garantie et ne devra pas être considérée comme valable.
REMEDES LÉGAUX DE L’ACHETEUR. Cette garantie limitée vous donne des droits légaux spéci-
fiques et il est possible que vous ayez d’autres droits qui varient d’un état à l’autre aux Etats-Unis
et d’un pays à l’autre. Vous avez également des droits de garantie implicite. En cas de problème
avec le service ou la performance suivant la garantie limitée, il est possible que vous puissiez intenter une action en justice devant la Cour des Prudhommes (“small claims court”), devant le tribunal
d’état ou devant le tribunal fédéral des Etats-Unis ou dans une autre juridiction appropriée en
dehors des Etats-Unis.
QUESTIONS. Toute question en ce qui concerne le respect des garanties énoncées dans les
présentes doit être envoyée, par écrit, à : Superwinch, Inc., Winch Drive, Putnam, CT 08260 U.S.A.
ou à Superwinch Limited, Abbey Rise, Whitchurch Road, Tavistock, Devon PL 19 9DR, England
GARANTIE LIMITÉ E
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
(see Figure 2) approximately doubles capacity of winch.
Figure 1
Freespool Clutch
In-Drum Brake
Remote Switch
Receptacle
Permanent
Magnet Motor
GENERAL DESCRIPTION
Integrated Solenoids
32
Thank you for purchasing an S 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; (1822) 614101 England.
When requesting information or ordering replacement parts; always give the
following information:
1. Winch Part Number
2. Serial Number (found on housing)
3. Part Number (found in Replacement Parts List section)
4. Part Description
Please read and understand this Owner’s Manual before installing your winch. Pay particular
attention to the 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. We have included several features in the winch to minimize this possibility; however,
your safety ultimately depends on your caution when using this product.
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.
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: The Superwinch S series winch is designed primarily for intermittent duty
general use. 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. Superwinch manufactures
a separate line of winches for industrial/commercial use. Please contact our Customer Service
Department for further information.
Congratulations on your choice!
INTRODUCTION
Roller Fairlead
Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º)
Lbs.**
kg**
12,563
5,698
8,503
3,857
6,527
2,961
3,213
1,457
ROLLING LOAD CAPACITIES
S3000
Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 lb. (1361 kg)
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/16" x 60'
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 1.3 hp (0.97 kW) peak
Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1
S4000
Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,000 lb. (1814 kg)
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/32" x 60'
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 1.8 hp (1.34 kW) peak
Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1
S5000
Working Load* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,000 lb. (2268 kg)
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4" x 50'
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24VDC 2.1 hp (1.57 kW) peak
Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159:1
* Based on first layer performance
SPECIFICATIONS
S5000
S4000
S3000
Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º)
Lbs.**
kg**
17,588
7,978
11,905
5,400
9,138
4,145
4,499
2,041
Slope* 10% (6º) 20% (11º) 30% (17º) 100% (45º)
Lbs.**
kg**
22,613
10,257
15,306
6,943
11,749
5,329
5,784
2,624
!
CAUTION
Description Quantity
Winch assembly with wire rope including lead wires 1
Circuit breaker assembly with hardware 1
Handsaver 1
Mounting hardware kit 1
Remote pendant 1
Owner’s manual 1
This carton contains the following items. Please unpack carefully.
Read instructions before beginning.
UNPACKING
DIMENSIONS
S3000, S4000, S5000
Figure 2
PERFORMANCE
Wire Rope Max. Pulling Capacity
Layer lbs. kg
1 3,000 1364
2 2,250 1021
3 2,000 907
4 1,750 794
Motor
Load Speed Current
lbs. kg ft/min m/min Amps
0 0 17.0 5.1 15
1,000 454 12.5 3.8 70
2,000 907 9.0 2.7 117
2,500 1134 7.5 2.3 155
3,000 1361 4.5 1.4 220
S3000
Wire Rope Max. Pulling Capacity
Layer lbs. kg
1 4,000 1818
2 3,000 1361
3 2,600 1179
4 2,000 998
Motor
Load Speed Current
lbs. kg ft/min m/min Amps
0 0 21.6 6.5 30
1,000 454 16.0 4.8 90
2,000 907 12.4 3.8 155
2,500 1134 10.6 3.2 180
3,000 1361 8.8 2.7 215
3,500 1589 6.2 1.9 250
4,000 1814 4.5 1.4 311
Wire Rope Max. Pulling Capacity
Layer lbs. kg
1 5,000 2273
2 4,000 1814
3 3,500 1588
4 2,900 1315
Motor
Load Speed Current
lbs. kg ft/min m/min Amps
0 0 17.5 5.9 36
1,000 454 14.5 4.6 80
2,000 907 12.0 3.4 135
3,000 1361 9.5 2.2 200
4,000 1814 7.3 1.3 265
5,000 2268 4.5 1.4 350
S4000
S5000
* Based on first layer performance
NOTES
1. All dimensions are in inches [millimeters].
2. Typical mount is to flat surface capable of handling the loads. Bolts to be Grade 5 or better.
6.0
(152)
15.1
(383)
7.2
(183)
7.1
(180)
3.1
(79)
5.9
(150)
3.69
(93.7)
1.24
(31.5)
ROLLER FAIRLEAD
SCREWS
DRUM SUPPORT
PLATE SCREWS
MOTOR
SCREWS
4 5
DRUM SUPPORT
PLATE
Your S series winch is a very powerful
machine. Treat it with respect, use it
with caution and always follow the
safety guidelines.
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. The S3000, S4000, and S5000
winch is rated at 3,000, 4,000,
and 5,000 pounds (1361, 1814,
2268 kg) (single line) capacity on
the wire rope layer closest to the
drum. 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 LOADS
OVER
2
/3RATED CAPACITY, WE
RECOMMEND THE USE OF THE
OPTIONAL PULLEY BLOCK TO
DOUBLE LINE THE WIRE ROPE
(Figures 3 & 18). 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.
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. 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 IS 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.
7
GENERAL SAFETY
INFORMATION
Figure 3
Single Line
Double Line
INTERMITTENT DUTY
An electric winch is like any other
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.
6
FEATURES
Electric Motor – 1.3 (S3000),
1.8 (S4000), 2.1 (S5000) peak hp
(.97 (S3000), 1.34 (S4000), 1.57
(S5000) kW) 12V or 24Volt
Permanent Magnet.
Braking – A wrap spring brake
which will hold 50% of rated load
on the first wrap. Reducing by
approximately 10% per layer
thereafter.
Drum – Die cast aluminum running
in maintenance free bearings.
Freespool Clutch – Operated by
an easy action lever which disengages the gearbox to allow the
wire rope to be pulled out without
using electric power. A tension
plate reduces backlash and snarling
when pulling out the wire rope.
Remote Switch – 30' (13.64 m)
hand held pendant switch assembly
with toggle switch.
Mounting – Optional custom
engineered mounting kits are available
for vehicle frame attachment.
European Union
Noise The noise level of this winch in operation is below 92 dB(A).
Emergency Stop In order to conform to Machinery Directive 89/392/EEC, each machine installation must be
fitted with an Isolator (Part Number 8370) whereby the machine can be brought safely to a complete stop.
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. ALWAYS USE
THE HANDSAVER when guiding
the wire rope in or
out (see Figure 4).
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.
Never guide a wire
rope onto the drum
with your hand.
9. NEVER HOOK THE WIRE ROPE
BACK ONTO ITSELF because you
could damage the wire rope.
Use a nylon sling (Figure 5).
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 6). 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 protection.
11. NEVER USE YOUR
WINCH FOR LIFTING
OR MOVING PEOPLE.
12. Your winch is not designed or
intended for overhead hoisting
operations.
13. AVOID CONTINUOUS PULLS
FROM EXTREME ANGLES as this
will cause the wire rope to pile
up at one end of the drum
(Figure 7). 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. STORE THE REMOTE PENDANT
ASSEMBLY IN A SAFE PLACE
when not in use to prevent use
by children or other unauthorized persons.
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.
22. When using your winch to move
a load, place the vehicle transmission in neutral, set vehicle parking 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.
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 could void your warranty.
26. Do not power the winch out for
more than 50 feet (15.2m) or
longer than 2 minutes.
The drum
and wire rope
may get very hot (Figure 8).
27. DO NOT CONNECT WINCH TO
EITHER 110V AC HOUSE CURRENT OR 220V MAINS AS WINCH
BURNOUT OR FATAL SHOCK
MAY OCCUR!
28. Never allow shock loads to be
applied to winch or wire rope.
29. 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.
GENERAL SAFETY
INFORMATION
(CONT.)
Figure 8
9
8
GENERAL SAFETY
INFORMATION
(CONT.)
Wrong Right
Right
Wrong
Figure 7
Figure 5
Figure 6
Figure 4
HOT!
Do not sub-
stitute any
strength grade weaker than
grade 5.
When attaching wires to the motor
terminals and solenoid (relay), hold
the inner nut when tightening the
outer nut. Do not allow the motor
terminals to rotate for it may cause
internal wire breakage or part misalignment. Be especially careful in
preventing the solenoid (relay)
terminals from rotating. Any
rotation can damage the solenoid
(see Figure 10).
Step (3)
Disconnect the vehicle battery
leads.
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.
Step (4)
Route the two (2) wires through
the vehicle grille 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 metal
parts of the vehicle. Attach the circuit breaker assembly to the end of
the blue terminated wire. Wrap the
circuit breaker assembly with electrical tape to prevent accidental
short circuits.
INSTALLATION
CONT.
11
Be Prepared
Figure 11
Figure 10
Superwinch mounting (fitting) kits
are available for most popular vehicles. If you can‘t locate a kit locally
contact Superwinch at the address
listed on the front of this manual
for the name of a Superwinch dealer
near you.
Detailed Mounting instructions are
provided with each mounting kit.
Read and follow directions carefully
to ensure proper winch alignment
and trouble free operation.
This winch
MUST be mounted with the wire rope in the underwind direction. Improper mounting
could damage your winch and void
your warranty.
MINIMUM ELECTRICAL
REQUIREMENTS
For 12 volt winches, a 60 ampere
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 and heavy duty
alternator are recommended.
Step (1)
Install mounting kit or structural
support for winch.
Step (2)
Mount the winch to the mount that
you have designed.
Mounting bolts supplied are the
correct length for use with up to a
1/4" (6.3mm) thick plate.
INSTALLATION
MOUNTING
YOUR WINCH
NOTES
1. All dimensions are in inches [millimeters].
2. Typical mount is to flat surface capable of handling the loads. Bolts to be Grade 5 or better.
6.0
(152)
15.1
(383)
7.2
(183)
7.1
(180)
3.1
(79)
5.9
(150)
3.69
(93.7)
1.24
(31.5)
10
ROLLER FAIRLEAD
SCREWS
DRUM SUPPORT
PLATE SCREWS
MOTOR
SCREWS
DRUM SUPPORT
PLATE
Figure 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.
Lift the clutch lever to the “Free”
position as shown in Figure 13. 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. Releasing 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
lever to the “Engaged” position
(see Figure 14).
Lever must
be in the
“Engaged” position and locked
before winching.
TIPS FOR EXTENDING THE LIFE OF
YOUR WINCH
1. KEEP THE WIRE ROPE TIGHTLY
WOUND ON THE DRUM. Do not
allow the wire rope to become
loosely wound. A loosely-wound
spool 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. 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. For pulling
at rated capacity, allow motor
to cool after 20 seconds of “On”
time. At loads less than 50
% of
rated capacity, allow to cool after
2 minutes of “On” time. 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
to double line heavier loads
(Figure 15).
13
Figure 14
FREE
ENGAGED
Figure 15
Note: If you choose to locate the
winch at a greater distance than
the wires provided will permit,
it may be necessary to purchase
a larger gauge wire to get the
best performance from your winch.
If the total length of additional
wire to be added to the system
exceeds 10' (3m), use a larger wire
gauge size.
Attach the circuit breaker directly
to the battery positive terminal,
and reattach the terminal to the
battery. If your vehicle is equipped
with side pole terminals, it may
be necessary to obtain auxiliary
side terminal bolts from your
localauto parts dealer to make
these connections.
Connect the remaining wire to the
battery negative terminal, and connect the terminal to the battery.
Step (5)
Lift the freespool clutch lever to
the “Free” position. Pull several
feet of wire rope off the drum.
Return the clutch lever back to
the “Engaged” position. Plug in
the remote pendant control.
Switch the slide lever to the
“Rope Out” position. Pull the
trigger momentarily to check wire
rope drum rotation and direction.
If the drum rotates in the wrong
direction, recheck your wiring.
The Hand-held pendant switch
activates a solenoid that activates
power to the winch motor. One
solenoid is for “Rope Out” motor
direction and the other is for the
“Rope In” motor direction (Fig. 12).
To prevent
unauthorized
use of the winch, remove pendant
control and store in a clean dry area
such as the glove box.
PENDANT OPERATION
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
(Figure 13) 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. (Fig.12)
The switch
assembly must
be kept free of dirt and moisture
to ensure safe operation.
12
INSTALLATION
CONT.
Figure 12
Cable In
Cable Out
A
B
DUST
COVER
Figure 13
HOT!
BRAKE OPERATION
Your S Series winch has a wrap
spring brake that stops and holds
loads up to 50
% rated capacity on
the first layer of wire rope closest
to drum.
Each additional layer of wire rope
reduces brake capacity approximately 10%. When powering the
winch in, the brake is disengaged
and does not become activated
until the motor is turned off and
the load tries to pull the wire rope
off the drum. When the winch is
powered out, as in releasing a load,
the brake is engaged and the motor
must over power the brake drag to
rotate the drum. Therefore, it is
normal for the winch to operate
faster in one direction than the
other. The brake is designed for the
wire rope to be used in the underwind position only. DO NOT OVERWIND. Powering against the brake
will cause heat to build up in the
drum and may transfer heat to the
wire rope (Figure 19). DO NOT
POWER OUT FOR MORE THAN 50
FEET (15.2m) OR 2 MINUTES.
The drum and
wire rope may
get very hot.
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.
15
Figure 19
4. The pull required to start a load
moving is often much greater
than the pull required to keep
it moving. AVOID FREQUENT
STOPS AND STARTS during pull.
5. PREVENT KINKS BEFORE THEY
OCCUR.
a. This is the start of a kink. At
this time, the wire rope should
be straightened.
b. The wire rope was pulled and
the loop has tightened to a
kink. The wire rope is now permanently damaged and must
be replaced.
c. Kinking causes the wire strands
under the greatest tension to
break and thus reduces the
load capacity of the wire rope.
The wire rope must be replaced.
6. EQUIPPING THE WINCH WITH A
ROLLER FAIRLEAD will substantially
reduce wear on the wire rope
during angle pulls (Figure 17).
The rollers eliminate heavy rubbing and abrasion to the wire rope.
Periodically check tightness of
mounting bolts and electrical connections. Remove any dirt or corrosion that may have accumulated
on the electrical connections.
Repair 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. If relubrication is necessary (after repair or
disassembly) only use Shell Alvenia
EP2 or equivalent.
REPLACING THE WIRE ROPE
Never substitute a heavier or lighter
wire rope. Never use rope made of
any material other than wire.
Always replace damaged wire
rope with manufacturer’s identi-
cal 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 18). 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.
14
MAINTENANCE
AND REPAIRS
Figure 16
a
b
c
Figure 17
Figure 18
1 Base 89-52021 1
2 Groove Pin 89-23303-01 2
3 Cable Guard 89-32268 1
4 Main Bearing 89-22268 1
5 M6 x 1 x 8mm Cup Pt. Set Screw 90-23164-12 1
7 Drum Bearing 89-22269 1
8 Drum Support 89-40092 1
9 Thrust Washer 90-12574 2
10 Drive Plate 89-32263 1
11 Rotating Ring Gear 89-32265 1
12 Planetary Carrier Assembly 89-22141 1
14 Sun Gear 89-33303 1
15 Stationary Ring Gear 89-32266 1
16 Free Wheel Repair Kit 89-10580 1
(Includes Shaft, Lever, Handle, and Rivet)
17 Free Wheel Spring 90-23152-08 1
18 M6 x 1 x 16mm Flat Head Screw 89-22291-01 4
20 Housing Assembly (includes 21 & 22) 89-40104 1
21 Needle Bearing (.8125 x 1.125 x .750) 89-23263-03 1
22 Motor Shaft Bearing 89-12002 1
23 S5000 Logo 89-17332 1
S4000 Logo 89-17331 1
S3000 Logo 89-17330 1
27 M6 x 1 x 13mm Button Head Screw 89-22290-01 2
29 Cable Tension Spring 89-32295 1
30 Handsaver 87-31120 1
31 Wire Rope Assembly w/hook 1/4"x50' (S5000) 1577A 1
Wire Rope Assembly w/hook 7/32"x60' (S4000) 1514A 1
Wire Rope Assembly w/hook 3/16"x60' (S3000) 1511C 1
32 M6 x 1 x 16mm Button Head Screw 89-22290-02 5
33 12 Volt Complete Motor (S5000) 90-33294 1
24 Volt Complete Motor 89-33298 1
12 Volt Complete Motor (S4000) 90-32295 1
24 Volt Complete Motor 89-33297 1
12 Volt Complete Motor (S3000) 90-33276 1
24 Volt Complete Motor 89-33296 1
37 Motor Cover 89-52024 1
38 “Superwinch” Nameplate 89-22277 1
39 M4 x 0.7 x 6mm Hex Washer Head Screw 89-22292-01 4
42 Drum 89-40085 1
43 Brake Spring 89-22342 1
44 Brake Adapter 89-22287 1
45 Roller Fairlead 89-40123 1
46 Roller Fairlead Frame 89-40113 1
47 Roller Fairlead Shaft (Long) 89-22334-02 2
48 Retainer Ring 90-23029-08 4
49 5/8 x 2.352 Roller 90-12568-04 2
50 5/8 x 4.735 Roller 90-12568-06 2
51 Roller Fairlead Shaft (Short) 89-22334-01 2
17
REPLACEMENT
PARTS LIST
Reference
Number Description Part Number Qty
Safety
69
WINCH ASSEMBLY
16
30
19
REPLACEMENT
PARTS LIST
Reference
Number Description Part Number Qty
TORQUE SPECIFICATIONS
Drum Support Plate 50-60 lb in
Screws
Hawse (Roller Fairlead) 45-55 lb in
Screws
Base Screws 65-75 lb in
Motor 35-40 lb in
TORQUE SPECIFICATIONS
Over torquing
could damage
your winch and void your warranty.
52 12V Wired Solenoid Assembly 89-32327 1
24V Wired Solenoid Assembly 89-32328 1
53
S3000, S4000 8AWG x 5' (neg.) Leadwire Assy. 89-23306-01 1
S5000 2AWG x 5' (pos.) Leadwire Assembly 89-22635-34 1
54
S3000, S4000 8AWG x 5' (pos.) Leadwire Assy. 89-23306-04 1
S5000 6AWG x 5' (neg.) Leadwire Assembly. 90-20187-06 1
55 Ground Strap 89-23356 1
56 5/16 Hel Spring Lock Washer 89-23227-08 1
57 5/16-18 Hex Nut 90-23149-07 1
60 6AWG x 3 1/2" Leadwire Assembly 90-23292-06 1
61 12V Solenoid 90-20329 2
24V Solenoid 90-20331 2
62 Buss Bar Assembly 92-10200 1
63 Buss Bar 92-20126 2
64
S3000, S4000 8AWG x 9 3/8" Leadwire Assy. 89-23292-21 1
S5000 6AWG x 9 3/8" Leadwire Assembly 90-20187-08 1
65
S3000, S4000 8AWG x 6" Leadwire Assembly 89-23306-02 1
S5000 6AWG x 6" Leadwire Assembly 89-23292-19 1
66 12V Solenoid Sub-Assembly 90-32250 1
24V Solenoid Sub-Assembly 90-32250-01 1
67 Socket Half Connector 90-25048 1
68 Remote Control Assembly 90-40270-02 1
69 Safety Label. 3/4" icon, 3 x 2 89-20330 1
18
ROLLER FAIRLEAD
SCREWS
MOTOR
SCREWS
DRUM SUPPORT
PLATE SCREWS
DRUM SUPPORT
PLATE SCREWS
67
68
61
54
52
64
63
62
61
60
56
57
55
53
65
63
SOLENOID ASSEMBLY
67
68
66
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