Superwinch SI Series, SI- 8K Hyd., SI- 10K Hyd. User Manual

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User’s Manual

SI Series, Hydraulic 8,000 & 10,000

Safety Precautions

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READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND

OPERATION OF YOUR SUPERWINCH

Table of Contents

1 INTRODUCTION

2 GENERAL SPECIFICATION DATA

INSTALLATION

3 HYDRAULIC SYSTEM

4 WINCH

5 ROPE

COMMISSIONING AND USE

6 FREESPOOL USE

7 TIPS FOR EXTENDING THE LIFE OF YOUR WINCH

MAINTENANCE

8 RUNNING IN, MAINTENANCE & SERVICING

9 HYDRAULIC SYSTEM TROUBLESHOOTING

PARTS

10 ACCESSORIES

11 WARRANTY

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1. INTRODUCTION

From all of us at Superwinch, “thank you.” We’ve built this winch to perform and
we’ve built this manual to help you get the most from your Superwinch.

Please read and understand this owner’s manual before installing your SI Series winch. You

industrial 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 unique features in
the Hydraulic Industrial winch to minimize this possibility; however, your safety ultimately
depends on your caution when using the product.

Pay particular attention to the caution notes preceded with the symbol shown here. The notes
contain advice for your safety and protection.

Please Note: The Superwinch SI Series winches are designed for total reliability. This winch is not
designed to be used in hoisting applications and Superwinch does not warrant it to be suitable
for such use.

WARNING, CAUTIONS AND NOTES

These warnings, cautions and notes are given throughout these instructions in the following
forms:

REPAIRS AND REPLACEMENTS

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Before contacting Superwinch or your nearest authorized Superwinch dealer, please have the
following information:

Part Number:

Serial Number of the Winch:

POISONOUS SUBSTANCES

Many liquids and other substances used should under no
circumstances be consumed, and should be kept away from
open wounds. These substances include (among others)

hydraulic oil.

SYNTHETIC RUBBER

Many ‘O’ ring seals, flexible pipes and similar items, when

subjected to fire or heat can become highly corrosive. Handle
with seamless industrial gloves only. Should skin contact occur,

remove contaminated clothing immediately and obtain medical assistance without delay.

RECYCLING AND THE ENVIROMENT

It is illegal to dispose of used oil in the ground, down sewers or
drains, or into waterways.

Dispose of used oil through an authorized waste disposal
contractor or recycling center. If in doubt contact your local authority for advice on how to
dispose of the oil or disposal facilities.

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2. GENERAL SPECIFICATION DATA

Type: Hydraulic Industrial

Gear Reduction: Planetary

Gear Ratio: 16:1

Drum: Steel Drum

Braking: Integral bi-directional, full load holding, hydraulically released,

spring applied brake.

Load Control: Optional Superblock Load Control Valve provides dynamic brake to

give a controlled stop on winch-out, under load. Brake opening
also assisted by Superblock.

Freespool: Operated either by an ergonomically designed handle, a cable

system, or by integral pneumatic device. Can be mounted to winch
side or top.

Mounting: Designed to meet most industry standard dimensions, 4 ½” x 10”

(254mm x 114.3mm). See 4) Winch Installation section of this
manual for more information.

STANDARD DRUM MODELS

Model Designation

SI- 8K Hyd.

SI- 10K Hyd.

Part Number

S100419

S100420

Weight (Less Rope)

107 lbs. / 48.5 kg

109 lbs. / 49.4 kg

Recommended Rope Diameter

3/8" / 9.5mm

3/8" / 9.5mm

Drum Capacity

169' / 51.5m

169' / 51.5m

Drum Diameter

3.5"/ 88.9mm

3.5"/ 88.9mm

Line Speed (1st Layer, No Load)

52 FPM / 15.8 MPM

31.5 FPM/ 9.6 MPM

Line Pull (Bottom Layer)

8,000 lbs. / 3628 kg.

10,000 lbs. / 4536 kg.

Operating Pressure

2200 PSI / 152 Bar

2050 PSI / 141 Bar

Oil Flow

15 GPM / 56.8 LPM

15 GPM / 56.8 LPM

LONG DRUM MODELS

Model Designation

SI- 8K Hyd.

SI- 10K Hyd.

Part Number

S100425

S100426

Weight (Less Rope)

111 lbs. / 50.3 kg

113 lbs. / 51.3 kg

Recommended Rope Diameter

3/8" / 9.5mm

3/8" / 9.5mm

Drum Capacity

202' / 61.5m

202' / 61.5m

Drum Diameter

3.5"/ 88.9mm

3.5"/ 88.9mm

Line Speed (1st Layer, No Load)

52 FPM / 15.8 MPM

31.5 FPM/ 9.6 MPM

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Line Pull (Bottom Layer)

8,000 lbs. / 3628 kg.

10,000 lbs. / 4536 kg.

Operating Pressure

2200 PSI / 152 Bar

2050 PSI / 141 Bar

Oil Flow

15 GPM / 56.8 LPM

15 GPM / 56.8 LPM

SHORT DRUM MODELS

Model Designation

SI- 8K Hyd.

SI- 10K Hyd.

Part Number

S100422

S100423

Weight (Less Rope)

105 lbs. / 47.6 kg

107 lbs. / 48.5 kg

Recommended Rope Diameter

3/8" / 9.5mm

3/8" / 9.5mm

Drum Capacity

135' / 41.1m

135' / 41.1m

Drum Diameter

3.5"/ 88.9mm

3.5"/ 88.9mm

Line Speed (1st Layer, No Load)

52 FPM / 15.8 MPM

31.5 FPM/ 9.6 MPM

Line Pull (Bottom Layer)

8,000 lbs. / 3628 kg.

10,000 lbs. / 4536 kg.

Operating Pressure

2200 PSI / 152 Bar

2050 PSI / 141 Bar

Oil Flow

15 GPM / 56.8 LPM

15 GPM / 56.8 LPM

HYDRAULIC SYSTEM RECOMMENDATIONS

Note: These parts are listed as minimum expectations for the Superwinch SI Series to perform to

its fullest.

System Type Open system with filtered return line

Relief Valve Set at winch operating pressure

Pump A max oil supply of 15 gallons per minute (57 Liters/ per minute) at top

motor RPM. The pump must be capable of delivering a pressure of 2320
PSI or 160 bar.

Reservoir Must be fitted with an oil filler device comprising of a strainer, an air filter,

and a dip stick. The capacity of the tank should be at least 15.8 gal (60 L).
Note: Do not fill the tank to the top, since there must be space for
expansion in the tank. Suitable hydraulic oil is Castrol CRML or
equivalent. Typical viscosity rating of 150 – 175 CST at 100 degrees C

Hoses Hoses should have a working pressure of 2900 psi (200 bar) or greater.

Pressure and flow loss is increased as hose length increases and/or bore
sizes decreases. Pressure and return lines in excess of 11.5 ft. (3.5 m)
should be compensated with an increase in nominal bore size.

Control Valve 4- way, 3- position self-centering with ports A & B to tank in the neutral

position and built in relief valve. The relief valve must be set at the winch
operating pressure. The valve should be mounted as close to the winch
as possible.

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Load Control Valve A load control valve provides dynamic braking to give a controlled

smooth strop on winch-out under load.

Hydraulic Motor 1/2" SAE O-ring boss ports

Oil Suction Strainer Rating Approx. 250 microns

Return line Filter Rating 10 to 40 microns

3. HYDRAULIC SYSTEM INSTALLATION

INSTALLATION

It is vital that all hose lengths are kept to a minimum. Pressure
and flow loss is increased as hose length increases and/or bore
size decreases. Pressure and return lines in excess of 11.5 ft.

(3.5m) should be compensated with an increase in bore size.

As a general rule: All installation work on a hydraulic system

should prioritize cleanliness and accuracy to insure the hydraulic

system functions properly.

HYDRAULIC CIRCUITS

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4. WINCH INSTALLATION

MOUNTING

The figures below show the mounting dimensions for the Hydraulic Superwinch SI 8,000
& 10,000. The Superwinch SI Series can be mounted foot down (see below) or in a traditional
foot-forward stance.

Due to the rating of these winches:

 Insure mountings are secure.
 Use only included hardware: M12 X 1.25 Grade 8 high tensile steel bolts
 Remember that the winch is only as strong as the plate and hardware it is mounted to.

Important: All eight mount holes should be used. Use only the
threaded holes provided, DO NOT drill and tap new holes in the
winch. DO NOT weld the winch or any parts of the winch to the
mounting plate.

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Precautions for foot down mounting

1. The winch must be bolted to at least a 1/4” (6mm) steel plate.

2. All four mounting holes in the bottom of each supporting casting must be used.

MOUNTING DIMENSIONS

After Mounting Check

After mounting and tightening all mounting bolts, place the winch in freespool and check the
drum rotation. If the winch is mounted incorrectly, it may bind causing poor freespooling and
decreased winch performance.

Binding drum? If the drum does bind, loosen all mounting bolts and rotate the drum once again
to see if it free rotates. Tighten the bolts one at a time, slowly, checking the drum rotation until
the winch is securely fastened. If the drum continues to bind, it could be that one or more of the
mounting system’s holes are out of position.

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5. ROPE INSTALLATION

Use caution when installing/using winch line. Incorrect

installation can lead to part damage. Follow these instructions.

Wire Rope: Wire rope must have a steel core.

Synthetic Rope: Superwinch recommends certified Dyneema synthetic ropes.

1. Unwind the rope from the spool and lay it out along the ground with the tapered end

nearest to the winch. NEVER wind the rope straight onto the drum from a coil.

2. Disengage the freespool

3. Insert the tapered end of the rope into the cross-hole in the end of the drum and secure

by tightening the setscrew. Synthetic rope only: insert tapered end of rope into the cross­hole and run across drum. Tape rope down and spool 5-6 wraps over the taped rope end.

4. Re-engage the freespool.

5. Carefully run the winch in the “Winch In” direction. Keeping tension on the rope. Spool

5 or 6 wraps of rope neatly onto the drum.

6. Apply moderate tension (approx. 1,500 lbs. or 680 kg to the rope). Carefully run the winch

in the “Winch In” direction. Ensure the layers are neatly wrapped onto the drum. This

will minimize damage to the lower layers of rope when a load is applied.

PULLING OUT THE ROPE

Insure no load is on the winch line then disengage the freespool.

With a pair of gloves on, pull out the rope and secure it to an

anchor or load. Check that there are at least 5 turns of rope
remains on the drum. Re-engage the freespool.

6. FREESPOOL OPERATION

Avoid pulling a load at more than a 15 degree angle in relation

to the winch. This will reduce wear and tear on the winch and

cable.

NOTE: The winch is designed such that it cannot be freespooled when the drum is under load.

MANUAL FREESPOOL OPERATION

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Insure no load is on the winch line. Note: Always use gloves
when working with winch rope.

1. To disengage the freespool (if engaged) pull up and rotate the clutch level to the

“Disengaged” position as shown below. If there is a load on the winch, the clutch lever
may not turn easily. DO NOT FORCE THE CLUTCH LEVER. Release tension on the winch,
by winching out hydraulically.

2. Pull the cable out by hand, but leave at least 5 wraps on the drum.

3. Engage the freespool by rotating the clutch lever to the “Engage” position, see the figure

below.

DO NOT ATTEMPT to pull a load until the drum is properly engaged.

4. Attach the load

5. Operate the winch.

7. TIPS FOR EXTENDING THE LIFE OF YOUR WINCH

1. KEEP A TIGHTLY WOUND ROPE DRUM

Do not allow the wire rope to become loosely- wound. A loosely-wound drum allows the
rope, under load, to work its way down into the layers of rope, cause it to bind and
possibly damage the rope.

2. USE A PULLEY BLOCK AND SHACKLET FOR HEAVY LOADS

To maximize the winch and rope life, use a pulley block and shackle to double line heavier
loads.

3. The pull required to start a load moving is often must greater than the pull required to

keep it moving. AVOID FREQUENT STOPPING AND STARTING during a pull.

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4. PREVENT KINKS IN THE WIRE ROPE BEFORE THEY OCCUR

(Fig. 5a) This is the start of a kink. At this time, the wire rope should be straightened.
(Fig. 5b) The wire rope was pulled and the loop has been tightened to a kink. The wire
rope is now permanently damaged and must be replaced.
(Fig. 5c) This is a result of kinking at different points, in each strand under a great load.
This will reduce the load capacity of the wire rope. The wire rope must be replaced.

8. MAINTENANCE & SERVICING

LUBRICATION

Freespool Handle (manual freespool version) - No need for lubrication, check to make sure the

freespool handle and shaft are free of debris.

Drum Bearings – Drum bearings are self-lubricating, no need for lubrication.

Gearbox – The gearbox is pre-lubricated from the factory. No need for lubrication

MAINTENANCE

After the first pull of the winch:

Check the tightness of the mounting bolts and hydraulic connections.

Monthly and Annually:

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Check the mounting bolts of the winch and the hydraulic connections. Make sure all connections
and bolts are tight. Check the cable for any kinks and breaks in the cable, if any are found, replace
cable before use.

SERVICING

Superwinch recommends factor-approved servicing only. Contact Superwinch for authorized
service centers.

9. HYDRAULIC SYSTEM TROUBLESHOOTING

Most hydraulic system failures follow the same pattern- a gradual or sudden loss of pressure or
flow with a resulting loss of power. Any one of the systems’ components may be at fault. By
following this step- by –step procedure, the trouble can be isolated in a short time.

Condition

Possible Cause

Operation

System Inoperative

No Oil in system

Fill system and check for leaks

Insufficient oil in system

Fill system and check for leaks

Wrong oil in the system

Refer to manufacturers'
specifications of the hydraulic
pump

Filter dirty or clogged

Drain oil and replace filter. Check
for leaks

Oil Line restriction. Oil

lines dirty or collapsed.

Replace damaged hoses. Change
oil

Leakage

Check all components, particularly
the relief valve, for proper
settings.

System Operates Erratically

Air in the system

Check the suction side of the
system for leaks. Repair

Cold Oil

Allow System to warm- up period

Dirty or damaged

components

Clean or repair as necessary

Restriction in filters or

lines

Clean and/or replace elements or
lines

System Operates Slowly

Oil viscosity is too high or

cold oil

Allow oil to warm up before
operating or change oil to a proper
viscosity.

Low Pump drive speed

Increase engine speed, refer to the
pump owner’s manual

Low Oil Level

Check reservoir and add oil as
necessary

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Improper adjustments

and Oil Leaks

Check relief valves, etc. Adjust per
manual of pump. Tighten all
fittings.

Overheating of Oil in the
system

Oil is passing through the

relief valve for an

excessive amount of time

Return control valve to neutral
when not in use, allow to cool
down

Incorrect oil, low oil, dirty

oil.

Use recommended oil, fill
reservoir, clean oil, replace filter

Excessive component

internal leakage

Repair or replace components as
necessary. Check system pressure

Malfunctioning oil cooler

Clean or repair

Insufficient heat

radiation

Clean dirt and mud from the oil
cooler and other components

Foaming of the Oil

Incorrect, dirty or low oil

Replace, clean or add oil as
needed

Air leaks

Tighten all fittings and check
suction line

Load Moves with Control
Valve in Neutral

Control valve not

centering when released

Check for spool binding and repair

Control valve handle is

not tight enough

Tighten handle and make sure the

valve is centering right

Control Valve Binding

Valve linkage misaligned

Repair

Valve Damaged

Replace

Drum will not rotate at all

Winch is not mounted

squarely

Checking mounting. Refer to

WINCH mounting page

Brake not disengaging

Check shuttle valve operation.
Check hose for leakage. Check

port for blockage. Disassemble &

inspect brake

Winch runs slow

Low Flow rate

Check flow rate. See hydraulic

systems flow spec page

Brake does not fully

disengage

Check to make sure pressures are

high enough to release the brake

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10. ACCESSORIES

Pulley Block

Part Number: 7755
Can double pulling power

Roller Fairlead

 Standard Drum P/N: S100506
 Short Drum P/N: S100507
 Long Drum P/N: S100508

Cable Tensioner

Standard Drum Part Number – S100500
Short Drum Part Number – S100501
Long Drum Part Number – S100502

Cable Clutch

2’ Cable Clutch Part Number – S102254
6’ Cable Clutch Part Number – S102226

Air Clutch

Air Clutch Small Frame Part Number –
S100512

11. WARRANTY

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Superwinch Limited Warranty

Valid World Wide

LIMITED WARRANTY. Superwinch (“Seller”) warrants to the original buyer (“you”) all parts and components except

wire rope to be free from defects in materials and workmanship for a period of (one) 1 year from the provable date of
purchase. Any Superwinch product which is defective will be repaired or replaced without charge to you, upon
compliance with these procedures. The warranties set forth herein are exclusive and in lieu of all other warranties,
whether oral or written, express or implied.
LIMITED WARRANTY PERFORMANCE PROCEDURE. Upon discovery of a defective Superwinch product, contact
the Seller or any Factory Authorized Service Centre written notice of such defect and mail, ship or otherwise deliver
the defective Superwinch, postage or shipping prepaid. Repairs or replacements by Seller under this limited Warranty
will normally be accomplished within fifteen (15) business days after receipt of the defective Superwinch. Seller or its
Authorized Agents may make reasonable charges for parts and labor for repairs not covered by this limited warranty.
WARRANTY AND REMEDY LIMITATIONS AND EXCLUSIONS. Repair and/or replacement of the defective
Superwinch or component thereof as provided herein is the exclusive remedy for the Buyer. The following exclusions
or limitations of warranties and limitations of remedies shall be expressly applicable:
A. Express warranties. Seller Warrants that the Superwinch is as described in the “Superwinch Owner’s Manual”
provided herewith; no other express warranty is made in respect to the Superwinch. If any model or sample was shown
to the Buyer, such model or sample was used for illustrative purposes only, and shall not be construed as a warranty
that the Superwinch will conform to the sample or model. SELLER MAKES NO EXPRESS WARRANTY WITH
RESPECT TO WIRE ROPE INCORPORATED IN THE PRODUCT.
B. Implied Warranties. THE IMPLIED WARRANTY OF MERCHANTABILITY AND ALL OTHER IMPLIED
WARRANTIES SHALL ONLY EXTEND FROM THE PROVABLE DATE OF PURCHASE FOR ONE (1) YEAR. THE
WIRE ROPE IS SOLD “AS IS”, WITHOUT ANY IMPLIED WARRANTIES. SOME STATES WITHIN THE USA DO NOT
ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT
APPLY TO YOU.
C. Incidental and Consequential Damages. SUBJECT TO SELLER’S LIMITED WARRANTY OBLIGATIONS SET
FORTH HEREIN, SELLER SHALL NOT BE RESPONSIBLE FOR INCIDENTAL DAMAGES OF ANY KIND, OR FOR
CONSEQUENTIAL DAMAGES TO PROPERTY, LOSS OF PROFITS AND LOSS OF USE WHICH MAY BE CAUSED
BY ANY DEFECT IN, OR MALFUNCTION, OR FAILURE OF ENCLOSED SUPERWINCH. SOME STATES WITHIN
THE USA DO NOT ALLOW EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
D. Condition of Warranty. Seller shall not be required to comply with its warranty duties provided herein if the defect,
malfunction, or failure of the Superwinch was caused by damage (not resulting from defective or malfunctioning
components) or unreasonable use by you. Unreasonable use shall include, but is not limited to, installation or use of
the Superwinch without compliance with the instructions contained in the Superwinch Owner’s Manual for the particular
model number. Seller’s liability under this warranty or for
any loss or damage to the Superwinch product shall not exceed the cost of correcting defects in or replacing the
Superwinch product, and upon expiration of the warranty period, all such liability shall terminate. The agents, dealers
and employees of the Seller are not authorized to make modifications to this warranty, or additional warranties binding
on the Seller. Accordingly, additional statements, whether oral or written, do not constitute warranties and should not
be relied upon.
LEGAL REMEDIES OF BUYER. This Limited Warranty gives you specific legal rights, and you may also have other
rights which vary from State to State within the USA and from country to country. You may also have implied warranty
rights. In the event of a problem with Limited Warranty service or performance, the Buyer may be able to go to small
claims court, a state Court or a federal district court in the USA or to appropriate jurisdictions outside the USA.
INQUIRES. Any enquiries regarding compliance with the warranties provided herein may be addressed in writing to
the address below.

13-1 WARRANTY

Superwinch

20750 S.W. 115th Avenue, Tualatin OR 97062

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U.S.A.
Tel: [phone]
Fax: [phone]

www.superwinch.com

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