Superwinch S4000 User Manual [en, es, fr]

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s’effectueront normalement dans les quinze (15) jours ouvrables suivant récep-

ables :

pas considéré une

CABLE MÉTALLIQUE INCORPORÉ AU PRO-

E DU VENDEUR

d’emploi

perte du produit Superwinch ou dommage à celui-ci ne dépassera pas le

r la présente garantie ni à donner

ème

Cour des Prudhommes (“small claims court”), devant le tribunal

rch Road, Tavistock, Devon PL 19 9DR, England

OWNER’S MANUA L

INSTALLATION • OPERATION • MAINTENANCE

E

SAFETY PRECAUTIONS • REPAIR PARTS

S4000 and S5000

12 & 24 Volt DC Electric Winches

With Remote Control

CAUTION

!

READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION

AND OPERATION OF YOUR SUPERWINCH PRODUCT.

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 3) 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: [phone] 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.

The responsibility for safe operation of this winch ultimately rests with you, the operator.
Read and understand all safety precautions and operating instructions before installing
and operating the winch. Careless winch operation can result in serious injury and/or
property damage.

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: 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

ROLLING LOAD CAPACITIES

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

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

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

SAFETY PRECAUTIONS

DANGER

!

WARNING

!

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

S4000, S5000

Figure 2

PERFORMANCE

Wire Rope Max. Pulling Capacity
Layer lbs. kg

1 4,000 1814
2 3,000 1361
3 2,600 1179
4 2,000 907

Motor
Load Speed Current
lbs. kg ft/min m/min Amps

0 0 21.6 6.6 30
1,000 454 16.0 4.9 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 1588 6.2 1.9 250
4,000 1814 4.5 1.4 311

Wire Rope Max. Pulling Capacity
Layer lbs. kg

1 5,000 2268
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 5.3 36
1,000 454 14.5 4.4 80
2,000 907 12.0 3.7 135
3,000 1361 9.5 2.9 200
4,000 1814 7.3 2.2 265
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 S4000 and S5000 winch is

rated at 4,000 and 5,000 pounds
(1814 and 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 & 15). 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.

WARNING

!

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 – 1.8 (S4000),

2.1 (S5000) peak hp, 1.34 (S4000),

1.57 (S5000) kW) 12V or 24V
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' (9.14 m)
handheld 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).
Battery Isolator 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.

CAUTION

!

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!

WARNING

!

MOUN T I N G

YOU R WINCH

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.

WARNING

!

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

DRUM SUPPORT
PLATE SCREWS

6.0

(152)

This winch
MUST be mou

nt-

I N S TA L L AT I O N

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
s

upport for winch.

Step (2)

When mounting the winch, pull the
freespool clutch lever into the freespool
position. Unwind 25-30 feet of rope
from the drum. This will provide the
access needed to install the mounting
bolts into the base plate mounting holes.

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”(6.3 mm)
thick plate.

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).

Figure 10

Step (3)

Disconnect the vehicle battery
leads.

I N S TA L L AT I O N

C O N T.

WARNING

!

Do not sub­stitute any

DANGER

!

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.

Figure 11

Automobile
batteries

Be Prepared

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 red wire. Wrap the circuit
breaker assembly with electrical tape
to prevent accidental short circuits.
Attach other end of circuit breaker
assembly to battery positive terminal.

ROLLER FAIRLEAD
SCREWS

Figure 9

1.24

(31.5)

3.69

(93.7)

5.9

(150)

3.1

(79)

7.1

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.

(180)

15.1

(383)

DRUM SUPPORT
PLATE

MOTOR
SCREWS

7.2

(183)

10

11

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. Press
the switch trigger to the “Rope­Out” position momentarily to
check wire rope drum rotation and
direction. If the drum rotates in
the wrong direction, recheck your
wiring. The Handheld 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

CAUTION

!

CAUTION

!

CAUTION

!

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.

WARNING

!

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

W INC H ASSEMBLY

REPLACEMEN T

PA R T S L I S T

Reference

5 M6 x 1 x 8mm Cup Pt. Set Screw 90-23164-12 1

52

Safety

(Includes Shaft, Lever, Handle, and Rivet)

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

27 M6 x 1 x 13mm Button Head Screw 89-22290-01 2

30

31 Wire Rope Assembly w/hook 1/4"x50' (S5000) 1577A 1

Wire Rope Assembly w/hook 7/32"x60' (S4000) 1514A 1
32 M6 x 1 x 16mm Button Head Screw 89-22290-02 5
33 12 Volt Complete Motor (S5000) 90-33294 1

12 Volt Complete Motor (S4000) 90-33295 1

38 “Superwinch” 177222-98etalpemaN
39 M4 x 0.7 x 6mm Hex Washer Head Screw 89-22292-01 4

ytQrebmuN traPnoitpircseDrebmuN

112025-98esaB1

210-30332-98niP evoorG2
186223-98drauG elbaC3
186222-98gniraeB niaM4

196222-98gniraeB murD7

129004-98troppuS murD8

247521-09rehsaW tsurhT9
136223-98etalP evirD01
156223-98raeG gniR gnitatoR11

114122-98ylbmessA reirraC yratenalP21

130333-98raeG nuS41
166223-98raeG gniR yranoitatS51

108501-98tiK riapeR leehW eerF61

180-25132-09gnirpS leehW eerF71

120021-98gniraeB tfahS rotoM22
123371-98ogoL 0005S32
113371-98ogoL 0004S

159223-98gnirpS noisneT elbaC92

102113-78 revasdnaH03

189233-98 rotoM etelpmoC tloV 42

181333-09rotoM etelpmoC tloV 42

142025-98revoC rotoM73

158004-98 murD24

124322-98gnirpS ekarB34
178222-98retpadA ekarB44

12235daelriaF relloR54

16

240-86521-09relloR 253.2 x 8/594

260-86521-09relloR 537.4 x 8/505
210-43322-98)trohS( tfahS daelriaF relloR15
103302-98lebaL ytefaS25

17

53

58

61

54

55

57

59

60

62

63

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.

WARNING

!

53 Leadwire spacer kit 89-24430 1
54 Buss bar kit 89-24431 1
55 Black 2 gage wire (-), S5000 12V 89-22635-61 1

Black 6 gage wire (-), S4000, S5000 24V 89-23292-38 1
57 Band clamp 89-14459 2
58 Red 2 gage wire (+), S5000 12V 89-22635-60 1

Red 6 gage wire (+), S4000, S5000 24V 89-23292-37 1
59 Socket 90-14140 1
60 Type 6 solenoid with bracket, 12V 89-24429 1

Type 6 solenoid with bracket, 24V 89-24467 1
61 Handheld remote control 90-33450-02 1
62 Ground jumper wire 18 gage 89-23283 1
63 Terminal adapter 89-14458 1

18

ROLLER FAIRLEAD
SCREWS

MOTOR
SCREWS

DRUM SUPPORT
PLATE SCREWS

DRUM SUPPORT
PLATE SCREWS

SOLENOID ASSEMBLY