Superwinch 1181 Instructions / Assembly
Contents
1. e E D Figure 5 Right wrong 14 Always operate winch with an unobstructed view of the winch ing operation 15 IT IS RECOMMENDED THAT A FAIRLEAD BE USED to guide the wire rope onto the winch Two types of fairleads are offered the Hawse Fairlead Part No 1507 and the Roller Fairlead Part No 1560 16 00 NOT OPERATE WINCH WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION 17 ALWAYS REMOVE THE SWITCH BEFORE WORKING IN AROUND THE WIRE ROPE FAIRLEAD OR WINCH DRUM THE DANGER ZONE so that the winch cannot be turned on accidentally 18 NEVER WORK ON OR AROUND THE FAIRLEAD OR WINCH DRUM WHEN WINCH IS UNDER LOAD 19 When using your winch to move load place the vehicle trans mission in neutral set vehicle parking brake chock all wheels and keep the engine running 20 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 down straps Contact your local Superwinch dealer 21 USE ONLY FACTORY APPROVED SWITCHES REMOTE CONTROLS AND ACCESSORIES Use of non fac tory approved components may cause injury or property damage and could void your warranty 22 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 23 Maintain 5 turns of wire rope around wire rope drum to pre vent the wire r2. 1 18 Rope Retainer Sem 1 5 Cable Tension Set 1 1 Fal of 38 Bohs amp Nuts 4 Flat Washers amp She ie tee a ck ase a B 2 Lacking washers De Di e Rope Hook Model 1177 i NS Pulley Block 2227 1 Hook Model 1177 90 22812 1 desde 3 16 x 50 Wire Rope amp Hook Assembly 1511A 1 Mem since FREE 12 AR denotes As Required 13 14 Freewheel Label Handsaver Label Repair Switch with 3 Leads Assembly of two Circuit Breakers on bracket 12 Assembly of two Circuit Braekers on bracket 24 Cable Retainer Pulley Block art Number 90 12520 3012417 1519 9022873 90 22873 01 90 23164 04 2227
3. create unsafe operating conditions FOR HEAVY LOADS WE RECOM MEND THE USE OF THE OPTIONAL PULLEY BLOCK AND HOOK ASSEMBLY PART NO 2227 TO DOUBLE LINE THE WIRE ROPE Figure 1 This reduces the load on the winch and the strain on the wire rope by approximately 50 5 single Line Double Line Figure 1 2 AFTER READING AND UNDER STANDING THIS MANUAL LEARN TO USE YOUR WINCH Practice using it so you will be familiar with it when the need arises Periodically check the winch installation to assure that all bolts are tight 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 opera tions Do not step over a taut wire rope or allow anyone else to do so Do not stand between the winch and load INSPECT WIRE ROPE AND EQUIPMENT FREQUENTLY A FRAYED WIRE ROPE WITH BRO KEN STRANDS SHOULD BE REPLACED IMMEDIATELY Always replace wire rope with the manufacturer s iden tical replacement part see Replacement Parts List Never replace the wire rope with any kind of rope other than the type and size specified in the Wire Rope section of this manual USE HEAVY LEATHER GLOVES when handling wire rope DO NOT LET WIRE ROPE SLIDE THROUGH YOUR HANDS A bro ken strand could seriously i
4. submerged in water The winch is weather resistant but not waterproof Superwinch mounting fitting kits are available for most popular vehi If you can t obtain a kit locally contact Superwinch at the address listed in this manual for the name of a Superwinch dealer near you Vertical Horizontal amp 5 MOUNTING CONT Drill two 716 12mm diameter holes with center lines exactly 3 11 16 93 66mm apart Figure 7 in the support chosen for the winch Attach the winch to the sup port with two 2 3 8 16 Hex Head Bolts Be sure the hardware is assembled as shown Tighten the hardware to 35 Ib ft torque Beet 5 Fat Washer Flat Washer Lock Washer ra Support ELECTRICAL INSTALLATION This winch operates on standard automotive 12 or 24 volt Direct Current CAUTION 299 winch fo 110 Volt house current Motor damage or fatal shock may occur B Prepared Automobile A WARNING 00606 tain gasses which are flammable and explosive Wear eye protection dur ing installation and remove all metal jewelry Do not lean over the bat ery while making connections The red wire from the switch is connected to the circuit protector terminal using the hardware pro vided The other end of the circuit protector is connected to the bat tery positive terminal The black wire from the switch is connected 6 to the battery negative terminal Figure 8 Be sure connection
5. HOOTING If the winch motor labors and then stops the load is too great Evidence of this will be a motor almost too hot to touch Repeated occurrence of this condition indi cates that the load exerted on your winch is beyond its capacity and may burn out the winch motor Use of the accessory pulley block P N 2227 will increase the winch s capacity MOTOR DOES NOT OPERATE Follow these steps in order Make sure your vehicle engine is running and then try operating your winch after each step 1 Remove switch then replace it on the motor making certain that it is aligned properly over brass motor connectors and that thumb screw is snug 2 If motor does not operate check all electrical connections on bat tery and ground making sure that they are clean and tight 3 Check the wiring harness to determine if all insulation is intact Damaged insulation could cause a short circuit TIPS FOR EXTENDING THE LIFE OF YOUR WINCH 1 KEEP A TIGHTLY AND EVENLY WOUND WIRE ROPE DRUM Do not allow the wire rope to become loosely wound loosely wound drum 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 10 windings damaging the wire rope To prevent this problem keep the wire rope tightly and evenly wound on the drum at all times During winching periodi cally check to see that the wire rope is w
6. IRLEAD P N 1560 Figure 19 will substantially reduce wear on the wire rope during angle pulls The rollers eliminate heavy rubbing and abrasion to the wire rope 11 2517 20 11 2 Number Qty w 1 Handsaver 893200 1 1 Mandsover Same T 2 tating Drive Shaft Assembly 90305701 1 2 Rang Gear Drum pr NN 3 Perimeter Bearing 9232 1 2 permete Bering 9232 1 1 Camer Bearing soa 2 5 Carer Bearing 3030 1 d Nanay deg Aint 1 Petry Gear any 3029199 1 u Nyon Step Washer 7 Mon Step Washer sot 3 rat Thrust Washer 1 8 10th Sun Gear Fi 1 9A Stationary Ring Gear w Needle Bearing g 1 H TA HP 12 Volt Motor wGearbox Needle Bearing 90 32425 1 x hater bunk pa Nese puni 1 3 HP 24 Volt Motor w Gearbox amp Needle Bearing 90 32429 1 vt Mato AE dh TOA Stationary Gear weed Bearing 3254 31 12 Bushing 90 12174 1 n Washer 90 2312011 1 13 5 16 Socket Head Cap Screw 9023056800 2 a Freespooling Knobshaft Assembly Legione Pen M socket Head Cap Screw 202508602 1 15 Repair Switch Assembly w two 3 ft leads includes 1519A 1 15 Pair of 3 8 Bolts amp Nuts 4 Flat Washers amp 90 22892 1 two butt splices for connecting to old harness 2 Locking Washers T Se x 25FCable Hoo ib Tm tase Hate 3030067 H TV circu Breaker Assembly 902283 1 17 Outboard Housing Fr XV Creat Breaker Asembiy d 2 Fange Bushing 5023620
7. SUPERWINCH OWNER S MANUA INSTALLATION OPERATION MAINTENANCE SAFETY PRECAUTIONS REPAIR PARTS MODEL X1 amp X1F 12 amp 24 Volt DC Electric Winches CAUTION READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF YOUR SUPERWINCH PRODUCT Superwinch Inc Superwinch Ltd Winch Drive Abbey Rise Whitchurch Road Putnam 06260 Tavistock Devon PL 19 9DR USA England Tel 860 928 7787 Tel 1822 614101 Fax 860 928 1143 Fax 1822 615204 90 10884 Rev 05 08 03 INTRODUCTION Thank you very much for purchasing a Superwinch product We hope and expect that you will be pleased with the performance and reliability of this unit If you are not for any reason please contact our Customer Service Department 860 928 7787 USA 1822 614101 England When requesting information or ordering replacement parts always give the following information 1 Winch Part Number 2 Part Number found in Replacement Parts List section 3 Part Description It is extremely important that you read and understand this Owner s Manual prior to installing and using your winch Pay particular attention to General Safety Information and be sure that anyone else who might use your winch also studies this section Pay particular attention to the caution notes preceded CAUTION with this symbol The notes contain advice for your protection UNPACKING This carton contains the following items Ple
8. ase unpack care fully Read instructions before beginning Description Winch assembly with wire rope and hook installed Switch and harness assembly with two 5 long 8 gauge wires Handsaver Gircuit breaker assembly with hardware Poly bag containing 2 bolts 2 washers 2 nuts 4 flat washers and 5 cable ties PERFORMANCE SPECIFICATIONS 1 1 1 1 1 I Working Load 2 000 Ibs 907 kg current Stal Load 2 500 Ibs 1 134 ko Easy wire Rope 3 16 x25 ft 32 0 0 25 76 30 Voltage 12 or 24 Volt DC 2000 907 9 27 200 13hp 24 0 0 25 76 20 Gear Ratio 123 1 2000 907 9 27 100 Weight ROLLING LOAD CAPACITY 18 Ibs 8 2 kg 30069 20 119 Lbs 10 000 6800 5200 2 600 kg 4535 3084 2359 1179 Ratings assume a 10 coeficient of con 1 A 10 slope is a rise of one foot in ten feet Siope in approximate degrees is also shown above Rl loads shown are for single line operation see Figure 1 Double Ine operation win optional g pully Bock PN 2227 approximately doubles capacity ot winch see Figure 1 Your new Superwinch is a powerful machine Treat it with respect use it with caution and always follow these safety guidelines 1 The X1 winch is rated at 2 000 Ibs single line capacity 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
9. ed from the winch when unattended to pre vent unauthorized operation Quickconnect Superwinch P N 1551 is available as an accessory to he winch Because the winch wil not hold a load in trailing or load holding applications tie down ropes or straps must ba used to secure loads Remote operation of the switch Figure 14 can be achieved by tying end of a cord through each ear ofthe switch MAINTENANCE Periodically check tightness of the mounting bolts and electrical connec tions Remove any dirt or corrosion that may have accumulated on the electrical connections 8 LUBRICATION Your new winch has lifetime lubrica tion There will be some grease leaking out of the winch especially during the first few operations This is normal and itis not necessary to grease or oll any part of the winch at any time WIRE ROPE A part of your winch that will require Periodic attention and eventual replacement is the wire rope Inspect the wire rope for wear frequently If fraying exists replace the wire rope at once Your winch uses 3 16 diameter galvanized aircraft type 7 x 19 wire Tope that is 25 feet long 4 200 Ib breaking strength Always replace the wire rope with Superwinch replace ment wire rope PIN 1511 see Replacement Parts Lis Figure 14 FREE SPOOL OPERATION MODEL X1F To disengage the clutch for free wheeling the wire rope out pull the knob at the wire rope
10. ed so the switch will mount properly only when installed as shown in Figure 11 Do not attempt to install the switch in the opposite direction If the switch is installed incorrectly and electrical contact made the winch will run in a direc tion opposite that is indicated on the product label resulting in possi ble operator injury Circuit Protector From Switch Red Solenoid Secure the switch to the motor by tightening the round thumb screw the outside of the switch Figure 12 The screw threads into the tapped hole between the brass motor contact Figure 11 Do not use pliers or over tighten the thumb screw Figure 12 After the switch is in place remove excess slack from the wiring harness in the vehicle by doubling over slack areas and tying securely Do not leave any dangling or loose wiring OPERATION SWITCH OPERATION itch springs back to the n an electrical shunt pro ic braking action which prevents the winch from coasting Figure 13 THIS BRAKING ACTION IS NOT A LOAD HOLDING DEVICE When the switch is centered in the OFF position the shunt reduces the action of a load backdriving the winch However a load can cause the winch to creep With the switch removed from the winch there isa greater ten dency for load to backdrive the winch ym Rope In Rope Out Figure 13 AWARNING asa Toad folding device The switch should be remov
11. end of the winch straight out and rotate the knob 90 1 4 turn The wire rope can be pulled out by hand Figure 15 Avoid jerking the wire rope off the drum when freespool ing as this can cause the wire rope to backlash and snarl on the drum Note The clutch cannot be released if there is a load on the wire rope To engage the clutch turn the clutch knob until the square key drops into the inner drum shaft Figure 16 Activate the control switch on the winch until the key drops into the outer drum shaft Check that the key is fully engaged before applying a load to the wire rope MAINTENANCE Periodically check tightness of the mounting bolts and electrical con nections Remove any dirt or corro sion that may have accumulated on the electrical connection LUBRICATION Your new winch has lifetime lubri cation There will be some grease leaking out of the winch especially during the first few operations This is normal and it is not necessary to grease or oil any part of the winch at any time WIRE ROPE A part of your winch that will require periodic attention and eventual replacement is the wire rope Inspect the wire rope for wear frequently If fraying exists replace the wire rope at once Your winch uses 3 16 diameter galvanized air craft type 7 x 9 wire rope 4 200 Ib breaking strength Always replace the wire rope with Superwinch replacement wire rope P N 1511 See pages 12 and 13 TROUBLE S
12. inding on evenly 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 small hill or incline and winch your vehicle up the indine 2 00 NOT ALLOW MOTOR TO OVERHEAT Remember the winch is only for intermittent use 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 If the motor is uncom fortably warm allow the motor to cool before continuing 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 P N 2227 to double line heavier loads Figure 17 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 A PULL 5 PREVENT KINKS BEFORE THEY OCCUR a This is the start of a kink At this time the wire rope should be straightened bb The wire rope was pulled and loop has tightened into a kink Wire rope is now permanently damaged and must be replaced lt The result of kinking is that each strand pulls a different amount causing strands under greatest tension to break and reduce load capacity of the wire rope The wire rope must be replaced 6 EQUIPPING THE WINCH WITH A ROLLER FA
13. njure your hands KEEP CLEAR OF THE WINCH WIRE ROPE AND HOOK WHEN OPERATING WINCH NEVER put your fingers through the hook when reeling in the last few feet of line If your finger should become trapped in the hook you could lose your finger Use the HAND SAVER BAR Figure 2 to guide the hook within the last few feet Never guide a wire rope or off the drum with your hand ss 8 NEVER HOOK THE WIRE ROPE BACK ONTO ITSELF Use a nylon sling Superwinch Part No 1509 Hooking the wire rope onto itself can damage the rope Figure 3 Wrong Figure 3 9 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 safety Figure 4 10 NEVER USE YOUR WINCH FOR LIFTING OR MOVING PEOPLE The winch is not designed nor intended for use in lifting or moving people 11 Your winch is not designed or intended for overhead hoisting operations 12 00 NOT ATTEMPT PULLS FROM ANGLES WITHOUT USING OPTIONAL FAIRLEAD PIN 1507 OR 1560 as damage to winch and wire may result 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 Tope in the winch causing dam age to the wire rope or winch itself
14. ope from pulling off under load 24 NEVER INSTALL WINCH IN SUCH A WAY THAT THE WARNING AND INSTRUCTION LABELS ARE OBSCURED Someone who had not read this manual may need to see them to understand the proper opera tion of the winch ALWAYS CHECK FOR CORRECT DIREC TION OF ROTATION BEFORE USING WINCH The winch must be properly wired to ensure cor rect direction of rotation 25 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 26 Always install winch in such a way that the operator will be standing with a comfortable posture with unobstructed access to and a clear view of the winch its labels and its controls INSTALLATION TOOLS NEEDED FOR MOUNTING AND WIRING Open End Wrenches 9 16 2 or small adjustable wrenches wire strippers or cutters terminal crimpers pliers torque wrench Pair 3 8 bolts and nuts four flat and two lock washers MOUNTING The mounting location for the winch must be capable of handling the loads of the job you intend the winch to do Suggested locations are flat front or rear bumper of a vehicle on a pickup truck bed or the winch stand on a trailer The winch can be mounted in a hor izontal or vertical position Figure 6 Do not mount the winch where there would be the possibil ity of it being
15. s are clean and tight Do not connect the switch or wiring to any other power source in the vehicle Circuit Protector f Chassis Ground Figure 8 Starting at the winch feed the Wires into the engine compartment If possible use the routing and sup port for the existing wiring If it is necessary to drill holes to feed the wires be sure the wires are protected from damage by using a grommet Figure 9 Use cable ties to secure wires along the route Grommet amp Tie Strap X Figure 9 When you make the ground con nection be sure to scrape off any dirt from the bolt that would pre vent a good connection Note If the winch is mounted at the rear of the vehicle a special wiring kit P N 1520 is available from Superwinch When extending the lead wires for rear vehicle mount always use 8 gauge wire or heavier to extend the existing wires to the battery Circuit Protector s Cable Figure 10 If connection to the battery positive terminal is not possible because of the terminal design connect the circuit protector to the starter solenoid hot side Determine the hot side by tracing the battery cable to the solenoid connection Connect the red supply wire to the same terminal to which the battery cable is connected Figure 10 Note Special adapters are available from your local Auto Parts Dealers for making connections to Side Post Batteries The switch and motor end are design
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