Superwinch S9000 User Manual [en, es, fr]

OWNER’S MANUAL

INSTALLATION • OPERATION • MAINTENANCE

SAFETY PRECAUTIONS • REPAIR PARTS

S9000

12 & 24 Volt DC Electric Winch

Model 1916, 1918

READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION

AND OPERATION OF YOUR SUPERWINCH PRODUCT.

90-17372 Rev - 5/12/04

Superwinch, Inc. Superwinch, Ltd.
Winch Drive Abbey Rise, Whitchurch Road
Putnam, CT 06260 Tavistock, Devon PL 19 9DR
U.S.A. England
Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone]

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 supplémen­taire, 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 spécifiques
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

GARANTIE LIMITÉE

CAUTION

!

2

Thank you for purchasing an S9000 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 (1916, 1918)

2. Serial Number (found on drum support casting)

3. Part Number (found in Replacement Parts List section)

4. Part Description

Please read and understand this Owner’s Manual prior to installing and using 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 can result. We have included several features in this 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.

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. If you intend
to install your winch on the front end of your vehicle use the mounting (fitting) kit
which has been designed and manufactured by Superwinch to accommodate your winch
and fit your vehicle.

Please Note: The Superwinch model S9000 winch is designed primarily for front mount
vehicle use and for other intermittent duty general use. This winch is not designed to be
used in hoisting applications and Superwinch does not warrant it to be suitable for such
use. Please contact our Customer Service Department for further information. Note the
electrical requirements of the S9000 winch you have purchased:

Part No. 1916 12-volt DC system Only
Part No. 1918 24-volt DC system Only

Congratulations on your choice!

Description Quantity

Winch assembly with wire rope 1
1/4-20 hex socket head cap screws 4
3/8-16 square nuts 4
3/8 flat washers 4
3/8 lock washers 4
3/8-16 hex head cap screw 4
Hand saver 1
7" Wire Ties 6
Clevis hook 1
Remote pendant assembly 1
Long lead wire assembly (color coded black) 1

INTRODUCTION

Electric Motor – 4.2 peak hp
(3.1 kw) 12 Volt Series Wound
or 3.5 peak hp (2.6 kw) 24 Volt
Series Wound.

Braking – A one way drag brake
will hold a 4,500 lb. (2041 kg) load
on the first wrap.

Drum – Fabricated steel running
in copolymer 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 spring­loaded drag mechanism reduces
backlash and snarling when pulling
out the wire rope.

Remote Switch – 15' (4.5m) hand
held pendant switch assembly.

Mounting – Optional custom engi­neered mounting kits are available
for vehicle frame attachment.

FEATURES

This carton contains the following items. Please unpack carefully.

Read instructions before beginning.

UNPACKING

3

Grade** 10% (6º) 20% (11º) 30% (17º) 60% (31º) 100% (45º)

Lbs.

kg

45,225
20514

30,600
13880

23,500
10659

15,000

6804

11,575

5250

* Ratings assume a 10% coefficient of friction.

** A 10% grade is a rise of one foot in ten feeet.Slope in approximate degrees is also shown.

ROLLING LOAD CAPACITIES*

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

Superwinch is not responsible for printing errors inadvertently made in the production of this manual.

DANGER

!

WARNING

!

CAUTION

!

5

PERFORMANCE

Your S9000 winch is a very powerful
machine. Treat it with respect, use it
with caution and always follow
these safety guidelines.

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. The S9000 winch is rated at 9,000

pounds (4082 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 6,000 POUNDS (2721
KG), WE RECOMMEND THE USE OF
THE OPTIONAL PULLEY BLOCK TO
DOUBLE LINE THE WIRE ROPE
(FIGURES 1 & 14). 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 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. 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 EVEN WHEN
WEARING GLOVES

.

GENERAL SAFETY

INFORMATION

Wire Rope Max. Pulling Capacity
Layer lbs kg

1 9,000 4082
2 7,365 3340
3 6,230 2825
4 5,400 2450
5 4,765 2160

Speed Speed Motor
Load* 12V 24V Current (Amps)
lbs kg ft/min m/min ft/min m/min 12V 24V

0 0 38.2 11.6 38.0 11.6 73 42
1,000 454 18.0 5.5 21.7 6.6 130 72
2,000 907 13.8 4.2 17.1 5.2 165 90
4,000 1814 9.0 2.7 12.0 3.6 240 133
6,000 2721 6.0 1.8 8.3 2.5 316 181
9,000 4082 2.5 0.8 3.5 1.0 420 252

INTERMITTENT DUTY

Working Load* . . . 9,000 lbs. (4082 kg)

Stall Load 12V*, 24V* . . . . . 12,700 lbs.

(5760 kg)

Wire Rope . . . . . . . . . . 5/16" x 100'

*Based on first layer performance.

12 V Motor . . 4.2 hp (3.1 kw) peak
24 V Motor . . 3.5 hp (2.6 kw) peak

Gear Ratio . . . . . . . . . . . . . . . 253:1

SPECIFICATIONS

4

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.

Figure 1

Single Line

Double Line

CAUTION

!

WARNING

!

DANGER

!

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. Your S9000 winch wire
rope has a ten-foot red “warning
indicator” on each end. The
“warning indicator” at the winch
end warns you that the wire rope
is near or less than 5 turns. The
“warning indicator” at the hook
end of the wire rope warns you
that the hook is approaching the
winch. ALWAYS USE THE HAND­SAVER when guiding the wire
rope in or out (see Figure 2). As
you use your winch, the red paint
will wear off due to normal use.
When this happens,
renew the red paint
as it is a safety fea­ture of the winch.

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 3).

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 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 protection.

11. NEVER USE YOUR
WINCH FOR LIFTING
PEOPLE 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 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. 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 who could injure
themselves or others.

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. To avoid overheating the motor,
do not power the winch out
longer than 2 minutes.

The drum and
wire rope may

get very hot (Figure 6).

27. DO NOT CONNECT WINCH TO
EITHER 110 VOLT 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.

6

7

Figure 2

GENERAL SAFETY

INFORMATION

(CONT.)

Wrong Right

GENERAL SAFETY

INFORMATION

(CONT.)

Right

Wrong

Figure 5

Figure 3

Figure 4

Figure 6

HOT

HOT

DANGER

!

NOTES:

1. All dimensions are in inches
(millimeters).

2. Winch is mounted with 3/8-16
(M 10) hardware. Using 1/4
inch (6.4) thick steel baseplate,
bolt length to be 1 inch (25.4).
Bolts to be SAE Grade 8
(ISO 10.9) or stronger.

3. Use only square nuts in casting
for mounting. (See Figure 8.)

MOUNTING DIMENSIONS

10 (254.0)

4 1/2

(114.3)

1 13/32 (35.7)

13/32 (10.3)
Dia. Holes
(4) Places

Alternate Construction of
Structural Reinforcement

Weld

4 1/8 (104.8)

7 1/2 (190.5)

1/4 (6.4)

1 3/8 (34.9)

1/2 (12.7)
Max. Rad.

1 9/16 (39.7)

5/32 (4.0)

19/32
(15.1)

7/8

(22.2)

13/32 (10.3) Dia.

10 5/16 (261.9)

3/16 (4.8)

Opening
1 3/16 (30.2)

9 (228.6) Opening

9

29. Always operate your winch in

an underwound orientation
only.

MOUNTING YOUR WINCH

Superwinch mounting (fitting) fits
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 install carefully to ensure
proper winch alignment and trou­ble-free operation.

If a Superwinch mounting plate is
not used, refer to Figure 7 for a
guide to construct a mounting system.

Note: This winch MUST be mount­ed with the wire rope in the under­wind direction.

Improper

mounting
could damage your winch, void
the warranty, and cause personal
injury.

MINIMUM ELECTRICAL
REQUIREMENTS

For 12 Volt winches, a 60 amp alter­nator and battery with 440 cold­cranking amperes capacity are the
minimum recommended power
sources. If the winch is in heavy use,
an auxiliary battery and heavy duty
alternator with battery isolator are
recommended.

TOOLS REQUIRED

Open End Wrenches (Spanners):

*(2) 3/8", *(2) 1/2", *(2) 7/16",
*(2) 9/16"

(1) 1/4 inch Hex socket wrench or

straight blade screwdriver

*Adjustable (Crescent) Wrenches may be substituted.

1. Install mounting kit or structural
support for winch.

2. Attach the long black color-coded
wire to the motor case (see
Figure 10). Mount the winch to
the mounting kit base plate or
to the mount that you designed
(see Figure 7).

The 3/8-16 mounting bolts sup­plied are the correct length for
use with a 1/4" thick Superwinch
mounting plate.

The end of the

mounting bolts
must not contact the opposite side
of the support casting’s mounting
pocket (see Figure 8).

Such contact could lead to a damaged
casting, catastrophic failure of the
winch and void the warranty. Adjust
bolt length accordingly if a thicker
plate is used. The bolt threads must
engage all the nut threads.

Always place the square nuts (pro­vided) in the casting pockets when
mounting your winch.

Do not sub-

stitute any
strength grade weaker than SAE
Grade 8 (ISO 10.9). Grade marking
is found on the bolt head and is
pictured in Figure 8.

3. 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 ft. (3m), use a larger wire
gauge size.

When attaching

wires to the
motor terminals and solenoids
(relays), hold the inner nut when
tightening the outer nut. Do not
allow the motor terminals to rotate
causing 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 9).

4. Disconnect the vehicle battery

leads.

Automobile bat-

teries 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.
(Fig. 11).

INSTALLATION

Figure 10

Support Casting

Mounting Pocket

Square Nut

Flat Washer

Lock Washer

(Must not
touch)

Grade 8 Bolt

Mounting
Plate

10.9

Figure 9

8

Figure 8

Figure 7

Red

Black

Be Prepared

Figure 11

Overwind

Underwind

CAUTION

!

CAUTION

!

WARNING

!

CAUTION

!

DANGER

!

5. Route the long red and long
black coded 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 red color coded wire
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 auxilliary side
terminal bolts from your local
auto parts dealer to make these
connections.

Connect the long black color
coded wire to the battery nega­tive terminal, and connect the
terminal to the battery.

6. Turn the freespool clutch lever to
the “Free” position. Pull several
feet or wire rope off the drum.
Return the clutch lever back to
the “Engaged” position. Plug in
the remote pendant control.
Activate the toggle switch
momentarily to check wire rope
drum rotation and direction. If
the drum rotates in the wrong
direction, recheck your wiring.

To prevent unau-

thorized use of
the winch, remove pendant control
and store in a clean dry area such
as the glove box.

Under some circumstances it may
|be appropriate to install additional
circuit protection devices (circuit
breakers). If in doubt, seek appro­priate expert advice. Superwinch
recommends that all winch electri-

cal systems can be readily and
quickly isolated from their electrical
supply in the event of an emer­gency. The winch electrical system
should always be isolated when
the winch is not in use.

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 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 toggle switch returns to the
“Off” position when released.

To change direction, move the
toggle in the other direction.

The switch

assembly must
be kept free of dirt and moisture
to ensure safe operation.

The switch

assembly must
be kept free of dirt and moisture
to ensure safe operation.

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.

Rotate 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,
then try releasing the clutch. 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 rotating the clutch
lever to the “Engaged” position
(see Figure 13).

Lever must be

in the engaged
position and locked before winching

TIPS FOR EXTENDING THE LIFE OF
YOUR WINCH

1. KEEP A TIGHTLY WOUND WIRE
ROPE 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. The internal
parts will be hotter than the case.
To check the motor temperature,
stop winching and carefully touch
the motor case, 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. To maximize winch and wire rope
life, use a pulley block to double
line heavier loads (Figure 14).

10

Figure 12

11

Figure 13

ENGAGED

FREE

Figure 14

OPERATION

Rope In

Rope Out

CAUTION

!

CAUTION

!

CAUTION

!

CAUTION

!

12

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 pull.

5. PREVENT KINKS BEFORE THEY
OCCUR.

6. EQUIPPING THE WINCH WITH A
ROLLER FAIRLEAD will substantial­ly reduce wear on the wire rope
during angle pulls (Figure 16).
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.

Repairs 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 factory
approved grease (Superwinch Part
No. 90-15020).

REPLACING THE WIRE ROPE

Never substitute a heavier or lighter
wire rope. Never use rope made of
any other material other than wire.

Always replace damaged wire
rope with manufacturer’s identi­cal 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 17). 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.

MAINTENANCE

13

Figure 15

a

b

c

a. This is the start
of a kink. Wire
rope should be
straightened.
b. Wire rope was
pulled and loop
has tightened into
a kink. Wire rope
is now permanent­ly damaged and
must be replaced.
c. Result of kink­ing is that each
strand pulls a dif­ferent amount caus­ing strands under
greatest tension
to break and
reduce load capac­ity of wire rope.
The wire rope
must be replaced.

Figure 16

Figure 17

BRAKE OPERATION

Your S9000 winch has a drag brake
that stops and holds loads up to
4,500 lbs. (2041 kg) 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. Drum must turn
clockwise, looking from motor
end, when winching in. 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 18). DO NOT POWER
OUT FOR MORE THAN 20 FEET (6m)
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.

Figure 19

Figure 18

HOT

HOT

HANDHELD REMOTE

DIRECTIONAL SWITCH

(Spring to Center)

HANDHELD REMOTE

DIRECTIONAL SWITCH

(Rope-In Position)

HANDHELD REMOTE

DIRECTIONAL SWITCH

(Rope-Out Position)

BLUE BLUE BLUE

YELLOWYELLOWYELLOW

BLACK

GROUND

BLACK

GROUND

BLACK

GROUND

RED

RED

RED

WHITE

WHITE

WHITE

BLACK

BLACK

BLACK

MOTOR

MOTOR

MOTOR

FIELD WINDINGS

FIELD WINDINGS

FIELD WINDINGS

OFF WIRE ROPE IN

WIRE ROPE OUT

BLUE

BLUE

BLUE

YELLOW

YELLOW

YELLOW

RED

RED

RED

DANGER

!

15

1

2

3

4

37

10

5

13

11

12

8

45

6

30

32

77

78

70

9

29

N

O

TE G

RO

O

V

E

O

RIEN

TATIO

N

D

15

16

17

27

28

56

55

54

57

53

58

53

60

51

50

49

44

43

42

41

40

39

38

68

65

36

35

34

81

33

80

7

31

46

59

14

1 12 VDC Motor 90-33333 1

24 VDC Motor 90-33334 1
2 Motor Spacer 90-10354 1
3 Ball Bearing 94-23079-05 1
4 1/4-20 x 5/8 Self tapping hex head screw 90-23039-10 3

6 Motor Adapter 90-32165 1
7 Outboard Drum Support w/ (10 & 37) 90-32257 1
8 Drum Bearing 90-12575 1
10 Winding Direction Label 92-10211 1
11 Drag Button Spring 90-23152-08 1
12 Drag Button 90-22612 1
13 Cover w/ Labels (specify model # when ordering) 90-40088 1
14 Drum 90-31069-04 1
15 M8 x 10 Socket Set Screw 94-23164-09 1
16 Drive Shaft Coupling 90-22110 1

17 Washer 90-23120-08 2
D Brake Assembly 90-25036 1
18 Not applicable this model ——
19 Not applicable this model ——
20 Not applicable this model ——

21 Not applicable this model ——
22 Not applicable this model ——
23 Not applicable this model ——
24 Not applicable this model ——
25 Not applicable this model ——

26 Not applicable this model ——
27 Drive Shaft Assembly 90-22254 1
28 Thrust Washer 90-12574 1
29 5/16 x 100 ft. Wire Rope w/o Hook 1580 1
30 Clevis Hook Assembly 94-20116 1

31 Inboard Drum Support w/ 37 90-32258 1
32 1/4-20 x 3 1/4 Socket Head Cap Screw 90-23015-05 4
33 3/8-16 Square Nut 90-23084-04 4
34 3/8 Flat Washer 92-23027-05 4
35 3/8 Lock Washer 92-23057-01 4

36 3/8-16 x 1 Hex Head Bolt, Grade 8 90-23226-01 4
38 Drum Bearing 90-12575 1
39 Drum Driving Plate 90-22183-01 1
40 Output Ring Gear 90-32232-01 1

REPLACEMENT

PARTS LIST

Reference
Number Description Part Number Qty

79

14

73

41 Ring Gear Bearing 90-22607 1
42 Carrier Bushing 90-10417 1
43 Planet Carrier Assembly 90-32238 1
44 Gearbox Bushing 90-10418 1
45 Plastic Closure 94-23171-05 2
46 8-32 x 3/8 Pan Head Screw 90-23032-17 1

47 Not applicable this model ——
48 Not applicable this model ——
49 Fixed Ring Gear 90-32233-01 1
50 Lock Pin 90-22252-01 1
51 Gearbox Housing (inc. 56-58, 60) 90-32296 1
53 1/4-20 x 5/8 Self Tapping Hex Head Screw 90-23039-10 4

54 Clutch Lever 90-32248 1
55 #8 Int Tooth Lock Washer 90-23048-03 1
56 Dust Cover 90-22103 1
57 Plug 94-23171-04 1
58 Rubber Washer 92-10194 2
59 Clutch Spring 90-23152-07 1

60 Push-on Retainer 90-23213-04 2
65 2 AWG x 8' Lead Wire Assembly (black) 90-22635-47 1
68 Handsaver 87-31120 1
NS 7" Long Wire Tie 94-23058-04 6
NS Grease (for one relube) 90-15020 1
ACC Roller Fairlead 2539 1

70 Remote Switch Pendant (15') 90-33450-01 1
71 Toggle Switch 90-14141 1
73 Connector Assembly w/ Wires 90-14140 1
77 12VDC Solenoid 90-14452 1

24VDC Solenoid 90-14454 1
78 Solenoid Mounting Plate w/ Studs 90-32436 1
79 10-32 x 1/2 Self Tapping Hex Washer Head Screw 92-23039-02 4

80 Tie Rod 90-20033 1
81 1/4-20 x 3/4 Socket Head Cap Screw 90-23055-06 2
NS 12V Motor Brush Repair Kit 90-10414-05 1

ACC 12V Circuit Breaker Assembly 2232 1
ACC 24V Circuit Breaker Assembly 2232A 1

NS Not Shown
ACC Accessory

REPLACEMENT

PARTS LIST

Reference
Number Description Part Number Qty

17

16

NOTES