Superwinch W115 User manual

OWNER’S MANUAL
INSTALLATION • OPERATION • MAINTENANCE
SAFETY PRECAUTIONS • REPAIR PARTS
W115
115V AC Electric Winch
Model W115
Part No. 1401
READ AND UNDERSTAND THIS MANUAL
BEFORE INSTALLATION AND OPERATION
OFYOUR SUPERWINCH PRODUCT.
90-10878 Rev - 05/08/03
Superwinch, Inc. Superwinch, Ltd.
Winch Drive Abbey Rise, Whitchurch Road
Putnam, CT 06260 Tavistock, Devon PL 19 9DR
U.S.A. England
Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone]

2
Thank you for purchasing a W115 winch from Superwinch. It has been
designed and manufactured to provide years of trouble-free operation. We
hope you will be pleased with its performance. If you are not, for any
reason, please contact our Customer Service Department:
[phone] USA; (1822) 614101 England.
When requesting information or ordering replacement parts; always give the
following information:
1. Winch Part Number 1401
2. Serial Number (found on housing)
3. Part Number (found in Replacement Parts List section)
4. Part Description
Please read and understand this Owner’s Manual prior to installing and using
your winch. Pay particular attention to the General Safety Information. Your
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 features in this winch to minimize this possibility; however,
your safety ultimately depends on your caution when using this product.
Pay particular attention to the caution and warning
notes preceded with the symbols shown here. The notes
contain advice for your protection.
Correct installation of your W115 winch is a requirement for proper
operation. Please Note: 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. Superwinch manufactures a separate line of winches for
industrial/commercial use. Please contact our Customer Service Department
for further information.
Note the electrical requirements of the W115 winch you have purchased.:
Part Number 1401 115 Volt 50/60Hz
Congratulations on your choice!
Description Quantity
Winch assembly with wire rope including lead wires 1
Hand saver bar 1
Mounting hardware kit 1
Owner’s manual 1
Risk of electric shock. Do not open. To reduce the risk
of electric shock, do not remove cover. No user
serviceable parts inside. Refer servicing to qualified
service personnel.
INTRODUCTION
This carton contains the following items. Please unpack carefully.
Read instructions before beginning.
UNPACKING
3
PERFORMANCE
Wire Rope Max. Pulling Capacity
Layer lbs. kg
1 1,000 454
2 875 397
3 800 363
4 700 317
5 625 283
6 550 249
SPECIFICATIONS
Motor Current
Load* Speed Amps
lbs. kg ft/min m/min 115V
0 0 23.0 7.0 3.0
250 113 19.0 5.8 5.0
500 227 17.0 5.2 7.0
750 340 15.0 4.6 8.0
1,000 454 13.0 4.0 10.0
Working Load* ...................................1,000 lbs. (454 kg)
Stall Load* ............................................1,500 lbs. (680 kg)
Wire Rope ......................................................... 5/32" x 45'
Voltage ............................................115, 50/60 Hz 1 phase
Motor......................................................... 0.6hp (0.45 KW)
Gear Ratio ....................................................................148:1
Duty Cycle 20 secs ON, 1/2hr. OFF, full load
* Based on first layer performance

Your W115 winch is a very powerful
machine. Treat it with respect, use it
with caution and always follow
these safety guidelines.
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. The W115 winch is rated at 1,000
pounds (454 kg) (single line)
capacity on the wire rope layer
closest to the drum. 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 create
unsafe operating conditions. FOR
LOADS OVER 750 POUNDS (340
KG), WE RECOMMEND THE USE
OF THE OPTIONAL PULLEY BLOCK
TO DOUBLE LINE THE WIRE ROPE
(Figures 2 & 17). This reduces the
load on the winch and the strain
on the wire rope by
approximately 50%.
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. KEEP WINCHING AREA CLEAR. Do
not allow people to remain in the
area during winching operations.
ALWAYS STAND CLEAR OF WIRE
ROPE, HOOK AND WINCH. IN THE
UNLIKELY EVENT OF ANY
COMPONENT FAILURE IT IS BEST
TO BE OUT OF HARM‘S WAY.
4. 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.
5. USE HEAVY LEATHER GLOVES
when handling wire rope. DO
NOT LET WIRE ROPE SLIDE
THROUGH YOUR HANDS EVEN
WHEN WEARING GLOVES.
6. NEVER WINCH WITH LESS THAN 5
TURNS of wire rope AROUND THE
WINCH DRUM since the wire rope
end fastener will NOT withstand
a load. ALWAYS USE THE
HANDSAVER BAR when guiding
the wire rope in or out (see
Figure 3).
GENERAL SAFETY
INFORMATION
4
Figure 2
Single Line
Double Line
Figure 3
5
7. 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. Never guide a
wire rope onto the drum
with your hand.
8. NEVER HOOK THE WIRE ROPE
BACK ONTO ITSELF because you
could damage the wire rope.
Use a nylon sling.
9. NEVER USE YOUR WINCH FOR
LIFTING OR MOVING PEOPLE.
10. Your winch is not designed or
intended for overhead hoisting
operations.
11. AVOID CONTINUOUS PULLS
FROM EXTREME ANGLES as this
will cause the wire rope to pile
up at one end of the drum. This
can jam the wire rope in the
winch, causing damage to the
rope or the winch.
12. NEVER OBSCURE THE WARNING
INSTRUCTION LABELS.
13. Always operate winch with an
unobstructed view of the
winching operation.
14. 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.
15. DO NOT OPERATE WINCH
WHEN UNDER THE INFLUENCE
OF DRUGS, ALCOHOL OR
MEDICATION.
16. 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.
17. 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 downs. Contact your local
Superwinch dealer.
18. USE ONLY FACTORY APPROVED
SWITCHES, REMOTE CONTROLS
AND ACCESSORIES. Use of non-
factory approved components
may cause injury or property
damage and could void your
warranty.
19. 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.
20. Never allow shock loads to be
applied to winch or wire rope.
21. 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.
22. BE SURE that the power supply
is disconnected before
performing maintenance or
repair procedures.
GENERAL SAFETY
INFORMATION
(CONT.)

This winch
MUST be
mounted with the wire rope in the
underwind direction. Improper
mounting could damage your winch
and void your warranty.
This unit may be mounted in either
a horizontal or vertical position, on
a wall or other suitable support. In
all installations, the unit must be
mounted so that the wire rope
feeds perpendicular to the drum
axis and does not rub across the
housing or base.
MINIMUM ELECTRICAL
REQUIREMENTS
The three-prong plug must be
plugged into a 115 Volt, AC
grounded outlet. Make sure that
the power supply cord is positioned
so that the moving load will not
damage it. Unplug the winch when
not in use. Electrical storms or line
surges can cause premature failure
of the internal bridge rectifier.
Drill two 7/16" (12mm) diameter
holes with centers 3 11/16" (94mm)
apart in the support choosen for
the winch. Attach the winch to the
support with the mounting hardwar
provided. Tighten the hardware to
35 pound foot torqu
Do not sub-
stitute any
strength grade weaker than ISO
grade 5.
The switch
assembly must
be kept free of dirt and moisture to
ensure safe operation.
OPERATION
This unit is activated via the switch
at the six foot cord. To remove wire
rope from the winch, depress the
“Out” button. The load will stop
without coasting when the button
is released. To pull a load or spool
wire rope onto the drum, depress
the “In” button. Your winch is
designed to pull 1,000 pounds in
single line for 20 seconds “On” time
on the wire rope layer closest to the
drum. Attempts to pull more than
this weight or exceed the duty cycle
may cause damage to the winch or
wire rope and could cause the
circuit breaker to trip, and the
winch will not operate. (See
“Trouble Shooting”.) Maintain a
minimum of five wraps of wire rope
67
MOUNTING
YOUR WINCH
around the winch drum before
attempting any pulls.
WIRE ROPE
A part of your winch that will
require periodic attention and
eventual replacement is the wire
rope. Inspect the wire rope
frequently. If it fraying exists,
replace the wire rope at once. Your
winch uses galvanized aircraft type
7 x 19 cable. Always replace the
wire rope with Superwinch
replacement rope, P/N 1527.
Because all rope is subject to wear,
it is excluded from our warranty.
The wire rope has been installed on
your winch under minimal load at
the factory. The wire rope must be
respooled onto the drum under
load so that the outer layers will
not draw down into the inner ones
thereby damaging the wire rope.
TIPS FOR EXTENDING THE LIFE OF
YOUR WINCH
1. KEEP A TIGHTLY WOUND WIRE
ROPE DRUM. Do not allow the
wire rope to become loosely
wound. A loosely-wound spool
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 windings damaging the
wire rope. To prevent this
problem, keep the wire rope
tightly and evenly wound on the
drum at all times. A good practice
is to rewind the wire rope under
tension after each use.
2. DO NOT ALLOW WINCH MOTOR
TO OVERHEAT. Remember, the
winch is for intermittent use only.
During long or heavy pulls the
motor will get hot. At 1,000 lb.
(454 kg) allow motor to cool after
20 seconds of “On” time. At loads
less than 500 lb. (227 kg) allow to
cool after 2 minutes of “On” time.
3. USE A PULLEY BLOCK FOR HEAVY
LOADS. To maximize winch and
wire rope life, use a pulley block
to double line heavier loads
(Figure 8).
4. The pull required to start a load
moving is often much greater
than the pull required to keep it
moving. AVOID FREQUENT STOPS
AND STARTS during pull.
5. PREVENT KINKS BEFORE THEY
OCCUR.
a. This is the start of a kink. At
this time, the wire rope should
be straightened.
b. The wire rope was pulled and
the loop has tightened to a
kink. The wire rope is now
permanently damaged and
must be replaced.
c. Kinking causes the wire strands
under the greatest tension to
break and thus reduces the
load capacity of the wire rope.
The wire rope must be replaced.
INSTALLATION
Flat Washer
Lock Washer
Nut
Bolt
Flat Washer
Support
3 11/16" (94mm)
Figure 8

98
LUBRICATION
The gearbox and drum bearing are
permanently lubricated with a high
performance gear lube. If
relubrication is necessary (after
repair or disassembly) only use Shell
Alvenia EP2 or equivalent.
REPLACING THE WIRE ROPE
Never substitute a heavier or lighter
wire rope. Never use rope made of
any other material other than wire.
Always replace damaged wire
rope with manufacturer’s
identical replacement part (See
Replacement Parts list). Pass
attaching end of wire rope through
the fairlead (if equipped) and attach
it to the drum with the retainer
provided with the replacement wire
rope.
It is important that the wire rope be
wound tightly onto the drum. A
good way to do this is to attach the
wire rope hook to a load and winch
it in.
MAINTENANCE
AND REPAIRS
ELECTRICAL SCHEMATIC
BLK
L
N
ORA
RED
MOTOR
CABLE OUT
CABLE IN
50 / 60 Hz
SWITCHES SHOWN IN
OFF POSITION
WHT
BLK
7A
WHT
GRN
(GRN/YEL)
115V
WHT
Periodically check tightness of
mounting bolts and electrical
connections. Remove any dirt or
corrosion that may have
accumulated on the electrical
connections.
Repair should be done by
Authorized Superwinch Repair
Centers ONLY. Do not attempt
to disassemble the gearbox.
Disassembly will void warranty.
TROUBLESHOOTING
CHART
Motor will not operate or
runs in one direction only
Motor runs extremely hot
Winch will not hold load
1. Circuit breaker tripped
2. Switch inoperative
3. Broken wires or bad
connection
4. Damaged motor
1. Long period of operation
2. Damaged motor
1. Excessive load
1. Reset Circuit Breaker.
If the winch fails to
operate, the end of the
motor should be
checked. If
the circuit breaker has
tripped, this will be
indicated by the center
portion of the breaker
protruding from the
main body. To reset the
breaker, merely press the
center portion back into
the assembly.
2. Replace switch
3. Check for poor
connections.
4. Replace or repair motor
1. Allow to cool
2. Replace or repair motor
1. Reduce load or double
line
Symptom Possible Cause(s) Corrective Action
If a problem arises, contact your nearest
Superwinch dealer or repair center.
Figure 9
a
b
c

10 11
1 Handsaver/Manual Handle 90-32031
3 Drum Assembly with Flange attached 90-32038
4 Perimeter Bearing 90-23137
5 Carrier Bearing 90-23140
6 Planetary Gear Builder 90-23138
7 Nylon Step Washer 90-12418
8 8 Tooth Sun Gear 90-23141
9 Flat Washer 90-23120-08
10 Motor w/Ring Gear & Primed Needle Bearing 90-32423-01
12 Flat Washer 90-23120-05
13 Bushing 90-12174
14 5/16" Socket Head Cap Screw 90-23056-02
15 Pair 3/8" Bolts & Nuts, 4 Flat & 2 Lock Washers 90-22892
16 Primed Base Plate 90-41019
18
Control Assembly w/6' Control Cord w/Switch & Power 90-32014
Supply Cord
19 Switch Assembly Only 90-23127
21 Cable Tension Plate Set 90-12450
22 5/32" x 45' Cable & Hook Assembly 1527
(2800 lbs minimum break strength)
23 Cable In Label 90-12386
24 Cable Out Label 90-12387
26 Handsaver Label 90-12417
27 Warning Label 90-10031
REPLACEMENT
PARTS LIST
Reference
Number Description Part Number
1
23
13
10
12
7
69
8
5
34
16
15
21
18
19
14
24
26
27
5
27
Black White
Green
Green
22