Superwinch SI Series Electric User Manual

User’s Manual
Read Owner’s
Use Hand Saver
Keep Clear of
Never Use
Never Use
Indicates an imminently hazardous situation which, if not avoided, will
The following symbols on the product and in the owner’s manual are used.
Read the Winch Users Guide for additional safety symbols.
SI Series Electric
Throughout this manual, you will find notations with the following headings:
result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation or unsafe practice which, if not avoided, could result in injury.
Indicates an unsafe practice which, if not avoided could result in property damage.
Manual
S101622 Rev. D superwinch.com | info@superwinch.com
Winch Rope and
Hook While
Operating
1
Winch to Lift
People
Winch to Hold
Load In Place
Safety Precautions
READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND
OPERATION OF YOUR SUPERWINCH
Table of Contents
1 INTRODUCTION
2 GENERAL SPECIFICATION DATA
INSTALLATION
3 WINCH
4 ROPE
5 ELECTRIC SYSTEM
COMMISSIONING AND USE
6 FREESPOOL USE
7 TIPS FOR EXTENDING THE LIFE OF YOUR WINCH
MAINTENANCE
8 RUNNING IN, MAINTENANCE & SERVICING
9 ELECTRICAL SYSTEM TROUBLESHOOTING
PARTS
10 ACCESSORIES
11 WARRANTY
S101622 Rev. D superwinch.com | info@superwinch.com
2
Read Owners
Use Hand Saver
Keep Clear of
Never Use
Never Use
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. Your 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 Superwinch 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:
The following symbols on the product and in the owner’s manual are used.
Read the Winch Users Guide for additional safety symbols.
Manual
Winch Rope and
Hook While
Operating
Winch to Lift
People
Winch to Hold
Load In Place
S101622 Rev. D superwinch.com | info@superwinch.com
3
REPAIRS AND REPLACEMENTS
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) battery
acid.
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.
S101622 Rev. D superwinch.com | info@superwinch.com
4
2. GENERAL SPECIFICATION DATA
Type: Electrical Industrial
Gear Reduction: Planetary
Gear Ratio: 16:1
Drum: Steel Drum
Braking: Integral bi-directional, full load holding, spring applied brake.
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.
3. WINCH INSTALLATION
MOUNTING
The figures below show the mounting dimensions for the 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.
S101622 Rev. D superwinch.com | info@superwinch.com
5
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.
S101622 Rev. D superwinch.com | info@superwinch.com
6
4. ELECTRICAL INSTALLATION
SI 8,000
SI- 8K
SI- 8K
SI 8K
SI 8K
SI 8K
SI 8K
Drum Capacity Maximum
135' /
41.1m
99mm
3.5"/
88.9mm
99mm
SI 10,000
SI- 10K
SI 10k
SI 10K
SI 10k
SI 10K
SI 10k
Part Number
S100420
S100429
S100426
S100435
S100423
S100432
Drum Capacity Maximum
135' /
41.1m
99mm
99mm
3.5"/
88.9mm
99mm
Winch Mounted Solenoid Box – simply connect red and black battery leads to proper battery terminals and secure.
Remote Mounted Solenoid Box – The SI Electric winch solenoid box can be remote mounted. Simply remove the solenoid box from the winch, find a suitable, flat location, and secure. A solenoid relocation kit, part XXXX, may be required.
5. ROPE SELECTION/INSTALLATION
SELECTION:
If your winch came without rope, please refer to the chart below on the diameter and length of cable/rope minimum and maximum requirements:
STANDARD DRUM WIDE DRUM NARROW DRUM
Model Designation
Part Number S100419 S100428 S100425 S100434 S100422 S100431
Recommended Rope Diameter
Drum Diameter 3.5"/ 88.9mm 3.5"/ 88.9mm 3.5"/ 88.9mm
Standard Drum J706
3/8" / 9.5mm 3/8" / 9.5mm 3/8" / 9.5mm 11mm
169' / 51.5m 169' / 51.5m 202' / 61.5m 51.7m
Standard Drum EN
WIDE Drum J706
WIDE Drum EN
NARROW Drum J706
3/8" /
9.5mm
NARROW Drum EN
11mm
51.7m
STANDARD DRUM WIDE DRUM NARROW DRUM
Model Designation
Recommended Rope Diameter
Drum Diameter 3.5"/ 88.9mm
Standard Drum J706
3/8" / 9.5mm 11mm 3/8" / 9.5mm 11mm
169' / 51.5m 51.7m 202' / 61.5m 51.7m
Standard Drum EN
WIDE Drum J706
3.5"/ 88.9mm
WIDE Drum EN
NARROW Drum J706
3/8" /
9.5mm
NARROW Drum EN
11mm
51.7m
S101622 Rev. D superwinch.com | info@superwinch.com
7
Use caution when selecting/installing/using winch line. Incorrect selection/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.
INSTALLATION:
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
S101622 Rev. D superwinch.com | info@superwinch.com
8
Insure no load is on the winch line. Note: Always use gloves
Engaged
Disengaged
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 powering the winch line out.
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.
S101622 Rev. D superwinch.com | info@superwinch.com
9
2. USE A PULLEY BLOCK AND SHACKLE 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.
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
S101622 Rev. D superwinch.com | info@superwinch.com
10
After the first pull of the winch:
SYMPTOM
POSSIBLE CAUSE
SOLUTION
Motor will not operate, or only
-Switch inoperative
-Replace switch Replace wires, connect
correctly and screw down the
-Replace or repair the motor
Motor runs but drum does not turn
-Clutch not engaged
-Engage clutch
Motor runs but with insufficient
-Weak battery
-Recharge or replace battery Keep connection terminals
clean, tighten or replace
-Repair or replace motor
Motor overheating
-Winch running for a long time
-Defective motor
-Allow to cool
-Replace motor
Check the tightness of the mounting bolts and electrical connections.
Monthly and Annually:
Check the mounting bolts of the winch and the electrical 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. ELECTRIC 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.
runs in one direction
power or low line speed
-Broken wires or bad connection
-Defective motor
-Defective motor
-
bolts
-
connective device
S101622 Rev. D superwinch.com | info@superwinch.com
11
10. ACCESSORIES
Pulley Block
Part Number: 7755 Can double pulling power
Cable Tensioner
Standard Drum Part Number – S100500 Short Drum Part Number – S100501 Long Drum Part Number – S100502
Roller Fairlead
Standard Drum P/N: S100506
Short Drum P/N: S100507
Long Drum P/N: S100508
Cable Clutch
2’ Cable Clutch Part Number – S102254 6’ Cable Clutch Part Number – S100514
S101622 Rev. D superwinch.com | info@superwinch.com
12
Air Clutch
Air Clutch Small Frame Part Number – S100512
11. WARRANTY
Superwinch Lim it e d War r anty
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 expres s war ranty i s mad e in r esp ect to t he S uperw inch. I f any model or sample w as 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
S101622 Rev. D superwinch.com | info@superwinch.com
13
CONSEQUENTIAL DAMAGES TO PROPERTY, LOSS OF PROFITS AND LOSS OF USE WHICH MAY BE CAUSED BY ANY DEFECT IN, OR MAL FUNCTION, OR FAILURE OF ENCLOSED SUPERW INCH. SOME STATES WITHIN THE USA DO NOT ALLOW EXCLUSION OR LI MITATION OF INCIDENTAL OR CONS EQUEN TIAL DA MAGES, 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 dut ies prov ided here in 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 w ith the instruction s contained in t he Superw inch Ow ner’s Manual for the parti cular 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 ar e not authorized to make modificat ion s to t h is w ar ranty , or ad ditio nal 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. 115
th
Avenue, Tualatin, OR 97062. U.S.A.
S101622 Rev. D superwinch.com | info@superwinch.com
14
Loading...