Superwinch SI Series Electric User manual

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User’s Manual
SI Series Electric
Throughout this manual, you will find notations with the following headings:
Read Owner’s
Manual
Use Hand Saver
Keep Clear of
Winch Rope and
Hook While
Operating
Never Use
Winch to Lift
People
Never Use
Winch to Hold
Load In Place
Indicates an imminently hazardous situation which, if not avoided, will
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.
The following symbols on the product and in the owner’s manual are used.
Read the Winch Users Guide for additional safety symbols.

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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

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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. 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.
Read Owners
Manual
Use Hand Saver
Keep Clear of
Winch Rope and
Hook While
Operating
Never Use
Winch to Lift
People
Never Use
Winch to Hold
Load In Place

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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.

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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.

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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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4. ELECTRICAL INSTALLATION
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:
SI 8,000
STANDARD DRUM WIDE DRUM NARROW DRUM
Model
Designation
SI- 8K
Standard
Drum J706
SI- 8K
Standard
Drum EN
SI 8K
WIDE Drum
J706
SI 8K
WIDE
Drum EN
SI 8K
NARROW
Drum J706
SI 8K
NARROW
Drum EN
Part Number S100419 S100428 S100425 S100434 S100422 S100431
Recommended
Rope Diameter 3/8" / 9.5mm 3/8" / 9.5mm 3/8" / 9.5mm 11mm 3/8" /
9.5mm 11mm
Drum Capacity
Maximum
169' / 51.5m 169' / 51.5m 202' / 61.5m 51.7m
135' /
41.1m
51.7m
Drum Diameter 3.5"/ 88.9mm 3.5"/ 88.9mm 3.5"/ 88.9mm
99mm
3.5"/
88.9mm
99mm
SI 10,000
STANDARD DRUM WIDE DRUM NARROW DRUM
Model
Designation
SI- 10K
Standard
Drum J706
SI 10k
Standard
Drum EN
SI 10K
WIDE Drum
J706
SI 10k
WIDE
Drum EN
SI 10K
NARROW
Drum J706
SI 10k
NARROW
Drum EN
Part Number
S100420
S100429
S100426
S100435
S100423
S100432
Recommended
Rope Diameter 3/8" / 9.5mm 11mm 3/8" / 9.5mm 11mm 3/8" /
9.5mm 11mm
Drum Capacity
Maximum
169' / 51.5m 51.7m 202' / 61.5m 51.7m
135' /
41.1m
51.7m
Drum Diameter 3.5"/ 88.9mm
99mm
3.5"/ 88.9mm
99mm
3.5"/
88.9mm
99mm
Use caution when selecting/installing/using winch line. Incorrect
selection/installation can lead to part damage. Follow these
instructions.

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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 cross-
hole 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 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.
Engaged
Disengaged

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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

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After the first pull of the winch:
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.
SYMPTOM
POSSIBLE CAUSE
SOLUTION
Motor will not operate, or only
runs in one direction
-Switch inoperative
-Broken wires or bad connection
-Defective motor
-Replace switch
-
Replace wires, connect
correctly and screw down the
bolts
-Replace or repair the motor
Motor runs but drum does not
turn
-Clutch not engaged
-Engage clutch
Motor runs but with insufficient
power or low line speed
-Weak battery
-Defective motor
-Recharge or replace battery
-
Keep connection terminals
clean, tighten or replace
connective device
-Repair or replace motor
Motor overheating
-Winch running for a long time
-Defective motor
-Allow to cool
-Replace motor

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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 – S100514

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Air Clutch
Air Clutch Small Frame Part Number – S100512
11. WARRANTY
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

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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 withoutcompliance 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. U.S.A.