OWNER’S GUIDE
UT3000 3000 LB 1361 kg
12 Volt DC Electric Winch
READ AND UNDERSTAND THIS GUIDE BEFORE
INSTALLATION AND OPERATION.
87-17427 Rev -
Superwinch, Inc.
Winch Drive
Putnam, CT 06260
U.S.A.
Tel: (860) 928-7787
Fax: (860) 963-0811
e-mail: info@superwinch.com
www.superwinch.com
Superwinch, Ltd.
Unit D, Union Mine Road
Pitts Cleave Ind Est
Tavistock, Devon
PL19 OPW England
Tel: 44 (0) 1822 614101
Fax: 44 (0) 1822 615204
e-mail: sales@superwinch.net
www.superwinch.com
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: Winch is designed primarily for intermittent applications. 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.
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
CAUTION
!
1
24
FONCTIONNEMENT
INTERMITTENT
Un treuil électrique est comme tout
autre outil à moteur tel qu'une scie ou
une perceuse électrique. Il ne faut pas
laisser le moteur électrique surchauffer.
Des précautions normales prolongeront
la durée de vie de votre moteur. Gardez
les durées de traction aussi courtes que
possible. Si l'extrémité du moteur
devient trop chaude pour le toucher
confortablement, arrêtez le treuillage
et laissez le moteur refroidir.
Pour plus d'information et la garantie
complète, visitez notre site Web à
www.superwinch.com
DANGER
!
WARNING
!
CAUTION
!
2 3
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. ALWAYS USE
THE HANDSAVER when guiding
the wire rope in or out (See
Figure 3).
9. NEVER HOOK THE WIRE ROPE
BACK ONTO ITSELF because you
could damage the wire rope.
Use a nylon sling (Figure 4).
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 5). If
a wire rope failure should occur,
the cloth will act as a damper
and help prevent the rope from
whipping.
11. NEVER USE YOUR
WINCH FOR LIFTING 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 on one end of the drum
(Figure 6). 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. NEVER WORK ON OR AROUND
THE WINCH DRUM WHEN
WINCH IS UNDER LOAD.
19. DO NOT OPERATE WINCH
WHEN UNDER THE INFLUENCE
OF DRUGS, ALCOHOL OR
MEDICATION.
Wrong
Right
Figure 4
Figure 5
Figure 3
Your winch is a very powerful
machine. If used unsafely or
improperly, there is a possibility
that property damage or personal
injury could result.
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. Maximum working load capacity
is on the wire rope layer closest
to the drum. DO NOT OVERLOAD. DO NOT ATTEMPT PROLONGED PULLS AT HEAVY
LOADS. Overloads can damage
the winch and/or the wire rope
and create unsafe operating conditions. FOR LOADS OVER 1/2
RATED CAPACITY, WE RECOMMEND THE USE OF THE OPTIONAL PULLEY BLOCK TO DOUBLE
LINE THE WIRE ROPE (Figure2).
This reduces the load on the
winch and the strain on the wire
rope by approximately 50%.
Attach hook to load bearing part.
The vehicle engine should be
running during winch operation. 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. 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.
7. NEVER WINCH WITH LESS THAN 5
TURNS of wire rope AROUND THE
WINCH DRUM since the wire rope
end fastener may NOT withstand
full load.
WARNING
!
WARNING
!
GENERAL SAFETY
INFORMATION
Figure 2
Double Line
Single Line
Figure 6
Right
Wrong
4
5
20. ALWAYS DISCONNECT WINCH
POWER LEADS TO BATTERY
BEFORE WORKING IN OR
AROUND THE WINCH DRUM 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
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.
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 CONNECT WINCH TO
EITHER 110V AC HOUSE CURRENT OR 220V MAINS AS WINCH
BURNOUT OR FATAL SHOCK
MAY OCCUR.
27. Never allow shock loads to be
applied to winch or wire rope.
28. 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.
INSTALLATION
Figure 7
Step (1)
Step (2)
Step (3)
[
[
[
FIGURE 7
Step (1)
Secure relay box to mounting
clamps by sliding into register, in
slots under relay box, slide clamps
around the motor and use washers
and square nuts supplied to attach.
Step (2)
Secure winch to mounting plate or
structural support using bolts,
lock washers and square nuts supplied with winch.
Step (3)
Remove bottom roller from the
roller fairlead. Pull & turn the free
spool knob to disengage and pull a
few inches of wire rope from the
drum. Pass the wire rope thimble
end under the remaining roller,
then replace the bottom roller. Next
secure the roller fairlead to mounting plate or structural support using
hardware provided.
Be sure that
both the mounting plate and winch hardware have
been properly tightened.
No part of the
vehicle (skidplates, wiring, auxiliary lights, tires,
etc.) should impede the operation
of your Superwinch. When mouting, check all vehicle and winch
parts for free operation. Be sure
that the winch mounting location
does not significantly reduce
ground clearance.
This winch
MUST be
mounted with the wire rope in the
underwind direction. Improper
mounting could damage your winch
and void your warranty.
Do not
substitute
any strength grade weaker than
ISO grade 4.6
WARNING
!
WARNING
!
CAUTION
!
WARNING
!
6
77
Step (4)
Disconnect the vehicle battery leads.
Batteries contain
gasses which are
flammable and explosive. Wear eye
protection during installation and
remove all metal jewelry. Do not
lean over battery while making
connections.
Step (5)
Refer to Figure 8 for wiring
diagram.
Route the two wires from the control box to the motor. Route the
two wires from the control box to
the battery. Attach the circuit breaker to battery end of the red wire.
Wrap the circuit breaker with electrical tape to prevent accidental
short circuits.
Apply several layers of electrical
tape where wiring may come into
contact with sharp metal parts of
the vehicle to prevent insulation
abrasion or cutting.
Attach the circuit breaker wire to
the battery positive terminal and
reattach the terminal to the battery.
Connect the remaining black control
box wire to the battery negative terminal and connect the terminal to
the battery.
Step (6)
Pull and turn (see Figure 9) the
freespool clutch knob to the “Free”
position. Pull several feet of wire
rope off the drum. Return the clutch
knob back to the “Engaged” position. Activate the winch in Cable
Out momentarily to check drum
rotation direction. If the drum
rotates in the wrong direction,
recheck your wiring.
INSTALLATION
FREESPOOL OPERATION
Pull and turn the clutch knob to the
“Free ” position as shown in Figure 9.
If there is a load on the wire rope,
the clutch knob may not pull out
easily. DO NOT FORCE THE CLUTCH
KNOB. Release tension on the clutch
by jogging out some of the wire
rope. Release 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
knob to the “Engaged” position.
(See Figure 9).
Clutch must be
fully engaged
before winching. Never engage
clutch knob while drum is turning.
If the winch
motor stalls,
do not continue to apply power.
Figure 8
Black
Black
Red
Red
Red
Battery
To Control
Box
To Battery
Circuit
Breaker
White
Washer
Red
Washer
WARNING
!
Figure 9
Engaged
Free
PENDANT OPERATION
The handheld pendant switch activates relays that feed 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 switch trigger 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.
To prevent
unauthorized
use of the winch, remove pendant
control and store in a clean dry area
such as the glove box.
Figure 11
Figure 10
Rope In
Rope Out
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
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