Superwinch 8569 User manual

Owner’sManual & FittingInstructions
Kit Nos. 8569, 8588, 8589
HYDRAULICALLY
POWERED
H9W
WINCH

Owner’sManual & FittingInstructions
Kit Nos:
8569, 8588, 8589
Theseinstructionscoverkitsfrom
22/08/02
01 INTRODUCTION
02 GENERALSPECIFICATIONDATA
INSTALLATION
03 HYDRAULIC SYSTEM
04 WINCH
05 WIRE ROPE
COMMISSIONING AND USE
06 TIPSFOREXTENDING THE LIFEOF YOUR WINCH
07 FREESPOOL USE
REMOTECONTROL OPERATION
MAINTENANCE
08 RUNNINGIN,MAINTENANCE AND REPAIRS
LUBRICATION
TROUBLESHOOTING
09 OPERATION
MISCELLANEOUS
10 ACCESSORIES
Superwinch Ltd.,
AbbeyRise, Whitchurch Road,Tavistock,Devon.
Great Britain.
PL19 9DR
Tel:[phone]
Fax:[phone]
[e-mail]
Superwinch Inc.,
Winch Drive,Putnam,Connecticut06260
U.S.A.
Tel: [phone]
Fax: [phone]
i

INTRODUCTION
INTRODUCTION
Please read andunderstandthisowner’smanual beforeinstalling your H9Wwinch. Your H9Wwinch isa verypowerfulmachine.If usedunsafely
orimproperly,thereis a possibility that property damageorpersonal injurycanresult.We haveincluded severaluniquefeaturesinthe winch to
minimise this possibility; however,your safetyultimatelydependson yourcautionwhenusingthe product.
Correctinstallation of yourH9W winchis arequirement for properoperation.
Pleasenote: The Superwinch H9W winch isdesigned for total reliability during vehiclerecoveryoperations.This winchisnotdesigned tobe
used in hoisting applications and Superwinchdoes notwarrant it suitablefor such use.
Superwinchreserve therighttoalter modelspecifications without prior notice.
PLEASEKEEPTHISOWNER’S HANDBOOK WITH THE WINCH.
Pay particular attentionto the caution notedprecededwith thesymbols shown here.The notescontain advicefor your protection.
WARNINGS,CAUTIONS AND NOTES
These are giventhroughthese instructions in thefollowingform :
WARNING :Procedureswhichmustbe followedprecisely in order to avoidthepossibility ofpersonalinjury.
CAUTION :Thiscalls attention to procedures whichmust befollowed to avoid damage to components.
NOTE:This callsattentionto methods which make a job easier or giveshelpfulinformation.
USAGEOFWINCH
This winch is designedfor useinapplications suchas:
Pulling
Hauling
Lifting (Vehicle RecoveryONLY)
and otherassociated uses.
POISONOUS SUBSTANCES
Many liquidsandothersubstances used should under nocircumstancesbeconsumed,andshouldbekept awayfromopenwounds.These
substancesinclude(amongothers)hydraulic oil.
SYNTHETICRUBBER
Many ‘O’ring seals, flexible pipesandsimilar items,when subjected to fireor heat can becomehighlycorrosive. Handlewith seamlessindustrial
gloves only.Shouldskin contactoccur,removecontaminatedclothingimmediatelyandobtainmedicalassistancewithoutdelay.Meanwhile,wash
the affected area withcopious amounts of cold wateror limewater for 15 to 60 minutes.
RECYCLING AND THE ENVIRONMENT
It is illegalto disposeof used oil in theground, down sewers ordrains or into waterways.
Dispose of usedoil through authorised waste disposalcontractors. If in doubtcontactyour localAuthority foradvice on disposalfacilities.
01
INTRODUCTION
01-1
SUPERWINCH winchesarenottobe used tolift, support or otherwise transport personnel.
Any such use shallbeconsideredtoinvalidate thewarranty andSuperwinch shallnot
beresponsible forany claims arising from such use.

GENERALSPECIFICATIONDATA
WINCH SPECIFICATION
Type .......................................................... H9W
GearReduction ........................................ SteelcentredPhosphorBronzewormwheeldriven bycasehardened, groundandpolishednickel
steelwormrunninginsubstantialrollerballbearing,mountedinaheat treated aluminium housing.
Oillubricated forguaranteed long life.
Gearbox Ratio .......................................... 54:1
Drum ........................................................ Fabricatedsteelrunningincopolymermaintenance freebearingswith springloadedbrakes to
prevent over-run when pullingout therope.
Braking...................................................... The action oftheworm and wormgear providesfor substantial brakingaction
Freespool.................................................. Multi-splinedfor low contactpressure. Operatedby an easy action lever which disengages thegear
box to allow the wire rope to bepulledoutwithout usingelectricpower.
Mounting .................................................. Ficingpositions allowfor platformorin-chassis mounting in either underoroverwinding modes.
Model Designation.................................... H9W H9W
PartNo. .................................................... 8569 8588 &8589
Rated Line Pull BottomLayer .................. 40kN(9000 lbs) 40 kN(9000lbs)
Line Speed 1st. Layer (NoLoad) ............ 7.3 M/min (24 ft/min) 7.3M/min (24ft/min)
Max.Oil Pressure .................................... 124 bar (1800 p.s.i.) 124bar(1800p.s.i.)
Max.Oil Flow............................................ 45l/min (12US Gal.min) 45 l/min(12 US Gal.min)
RopeDiameter(Recommended).............. 10mm 10 mm
RopeLength ............................................ 14m(45 ft) 28 m (90ft)
Drum Diameter ........................................ 76.2mm (3”) 76.2 mm(3”)
Weight ...................................................... 28.5kg (63 lbs) 28.5 kg (63lbs)
HYDRAULIC SYSTEMSPECIFICATION
System Type ................................ Open system with filteredreturn line.
ReliefValve .................................. Set atwinch operating pressure.
Pump............................................ Withamax.oilsupplyof 60l/min(16U.S. gal/min) attopmotor rpm.Thepumpmustbecapable
ofdelivering a pressure of 130bar(1890lb/ in
2).
Reservoir...................................... Mustbefittedwithanoil filler devicecomprisingstrainer andair filter and adipstick. Thecapacityof
thetankshouldbeat least60litres(16U.S.gal).Note.Don’t fill thetankto thetop,since theremust
bespaceforexpansioninthetank.Suitable hydraulicoil isCastrolCRMLor equivalent(150LHM
32-68). Typicalviscosityrating of150-175cSTat 100°C (695-816SUSat212°F).
Hoses .......................................... Shouldhave theminimumfollowingdimensions:
Pressureand flow loss is increased as Pumpinlet line:1/2”NominalBore (N.B.).
hose length increases and/or bore size (reservoir to pump)
decreases. Pressure andreturn lines Return line:3/4” N.B.
nexcess of3.5 metres shouldbe (controlvalveto reservoir)
compensated withan increase in Pressure hoses :1/2”N.B.(Pipe;18x2mm -3/4” SCHED 80)
inominalbore size. (controlvalveto load control valve)
Pilotline, pipe :0 8-10 x 1mm -3/4”SCHED80
Motor caseDrain Line(Optional)1/4” Min. bore.
Controlvalve................................ 4-way,3-positionwithspring centred,closedcentre and builtinrelief valve. The reliefvalvemustbe
setatthewinch operating pressure. Thevalveshould be mountedasclosetothe winch as possible.
Hydraulic motor............................ Todrain line in necessary.SAE ported andfitted withBSP adaptors.
Oil Suction Strainerrating............ Approx.250 microns (0.010”).
Return Line Filter rating .............. 10-40 microns (0.0004”-0.0016”).
0
2
02-1
GENERAL SPECIFICATION DATA

HYDRAULIC SYSTEM INSTALLATION
INSTALLATION
Refer toHydraulicSystem Specification.
IMPORTANT: It isvitaltoensure thatall hoselengthsarekepttoaminimum.Pressure andflowloss isincreased ashoselength
increasesand/or bore size decreases. Pressure andreturnlinesin excess of 3.5meters(11.5’) should be compensated with an increase
innominalbore size.
As ageneral rule;
BiggerNominal BoreHose= BetterWinch Performance.
In allinstallationwork ona hydraulicsystem,cleanlinessandaccuracy are essentialsothatthe hydraulicsystem functions properly.
Fig.2
03
HYDRAULICSYSTEM INSTALLATION
03-1

WINCHINSTALLATION
WINCH INSTALLATION
1. Thehydraulic motor should be bolted into position using them12boltsandwasherssupplied.
2. Refer tothe mountingdiagram (Fig. 3).Alldimensions are inmm.
3. Winchmounting can be via awinch mount plate(Part No. 7840,not 8569).
4. Thewinch(together with it’smountingplate iffitted)mustbesecurelyboltedontoamountingsurfacethat isflattowithin0.5mm and
sufficiently stiff to preventflexing. Aminimum of6.4mm (0.25”)thick steelplate should beused.Remember thatthe winch is only asstrong
as it’smounting.
5. All four mounting holes marks ‘A’mustbe used.
6. Use the spacers provided.
7. Althought thewinch may be mounted in either the‘overwound’or‘underwound’positions,‘underwound’isrecommended.
8. Mounting bolts mustbe 8.8grade HighTensile Steel.
0
4
WINCH INSTALLATION 04-1
A
C
D
C
WINCH DIMENSION A DIMENSION C DIMENSION D
8569 349mm [13.8”] 197mm [7.8”] 210mm [8.3”]
8588 414mm [16.3”] 262mm [10.3”] 275mm [10.8”]
8589 414mm [16.3”] 262mm [10.3”] 275mm [10.8”]
OVERWOUND POSITION(NOTRECOMMENDED)
Fig.3

WIRE ROPE INSTALLATION
WIRE ROPE SPECIFICATION
Theropemust be goodquality, havea steelcore. Referto theCertificate of Conformity forfull details.
WIRE ROPE INSTALLATION
Whenthewinchis suppliedfromthe factory withoutwire ropefitted,youshouldinstalltheropeinthefollowingsequence. Theinstallationofa
ropeisasimpleprocedure.It isagoodideatohave someone helpyouwiththis.Firstmake sure theremotecontrolisunpluggedto prevent
unathorisedusewhen yourworking around the ropestorage drum.
1. Unwindthecablebyrollingit out alongtheground withthetaperedendnearestto the winch.Never windthecable straightonto the drum
from acoil (Fig. 5).
2. Move the Clutch Handle to the“Disengaged” positionas shown in Fig. 4.
3. Insert the taperedendoftheropethroughthefairleadandonto the drum.Intheoverwoundposition, passtheropestraightintotherope
fixing hole. In the overwoundposition, pass theropeundertheropedrumandthread theropeintothe fixing holefrom drum.Fix the endof
theropewith thesetscrew.
4. Move the ClutchHandleto the “Engage” position(Fig. 4). Connecttheremote control. Iftheleverdoesnotslideeasilyinto engagement, it
may benecessaryto momentarily operate thecontrol switchthenrelease to theoff position.
5. Carefully run thewinch in the“WinchIn” direction.Keepingtensiononthe cable spool 5or 6 wraps of cableneatly onto thedrum.
6. Applymoderate tension(approx. 1500 kg) to the rope.
Thismay be achieved byanchoringtherope hook(with a sling) to atreeand winching the vehicletowardsthe treewiththebrakesappliedlightly.
Takecareto ensurethelayersareneatlywrapped. Thiswill minimise damageto the lowerlayersofrope whenaloadisapplied. Usethe
handsaverbarto guide theropethe last fewfeet onto thedrum.
NOTE:Where a wire ropeisnotsupplied, or whenreplacing awire rope,always use a Superwinch recommendedwire rope.
PULLING OUTTHE WIRE ROPE
MovetheClutchHandletothe “Disengaged” position.Pullout theropeandsecureto anchor or load,checkthat thereareat least5turnsleft on
thedrum.
Re-engage theDrum bymovingthe ClutchHandletothe “Engage”position(Fig.4). If thehandle does not slideeasily into engagement, it may
be necessary tomomentarilyoperate thecontrolswitchthenrelease to theoff position.
DISENGAGED
(FREESPOOL)
ENGAGED
(WINCH)
Fig.4 Fig.5
05
WIRE ROPE INSTALLATION
05-1

TIPSFOR EXTENDING THE LIFE OFYOUR WINCH
TIPSFOR EXTENDING THE LIFEOF YOUR WINCH
1. Keepatightly woundropedrum.Do notallow thewire ropeto becomelooselywound.Aloosely-woundspoolallowsawireropeunder
loadto workitswaydowninto the layersof wirerope on tothedrum. Whenthis happens,thewirerope maybecome wedgedwithinthe body
ofthewindingsdamagingthewire rope.Topreventthisproblem,keep the wire rope tightlyandevenlywoundonthedrumatalltimes.A
goodpractice istorewindthewire ropeunder atensionofapprox.500kgafter each use.Forexample,thiscan beachievedbyattaching
thehook to acarand recoveringwith thewinch using thecar’sbrakes to control theload.
2. Do not allow motortooverheat.Remember,thewinchisforintermittentuseonly.Duringlongor heavy pullsthemotorwill gethot.The
internalpartswill be hotter thanthe case.Tocheckthe motor temperature,stopwinchingand carefullytouch themotorcase, if the motoris
uncomfortably warm, allowthemotorto coolbefore continuing -keep theenginerunning to rechargethe battery during this break.
3. Useapulleyblockandshackle forheavyloads.Tomaximisewinchandwireropelife,useapulleyblock andshackle todoubleline
heavierloads.
4. The pull required to start a load moving isoftenmuchgreaterthan thepull requiredto keepitmoving.Avoidfrequentstoppingand starting
duringapull.
5. Prevent kinksbefore theyoccur.
(a) This is the start ofa kink.At thistime,theropeshould be straightened.
(b) Theropewas pulled and theloophastightened to akink.The rope isnow permenantly damagedandmust be replaced.
(c) Theresult ofkinkingisthat eachstrandpullsadifferentamountcausingthestrandsundergreattensionto break andreduceload
capacity of thewire rope.The wire rope mustbereplaced.
Fig. 6
0
6
TIPS FOR EXTENDING THE LIFE OF YOUR WINCH 06-1

WINCHOPERATION
FREESPOOL OPERATION
When wirerope isremovedfrom thedrum,asinbringingthe hook tothe load,the freespoolfeature ofthewinch shouldbe used.
To Engage:
TurntheFreespoolHandleto the“Engaged” position. Pullthe ropeout (wearinga pair of gloves) until the Freespoolpin engages(resistance
is felt).
To Disengage:
Turn the FreespoolHandle to the“Disengaged” position.
DISENGAGED
(FREESPOOL)
ENGAGED
(WINCH)
Fig.7
07
WINCH OPERATION
07-1

RUNNING IN, MAINTENANCEAND REPAIRS
RUNNING-IN PROCEDURE
IMPORTANT
Ensure yourwinch wormboxhasbeenfilled with oilprior to use.
MAINTENANCE AND REPAIRS
Periodically checktightness ofmounting bolts andelectrical connections. Removeanydirtor corrosion thatmay
have accumulated on the electricalconnections.
Repair should be carriedoutby AuthorisedSuperwinch Repair Centresonly.Do not attemptdisassemblyof the
gearbox. Disassembly will void warranty.
After the first1hourof operation: Changethe Gearbox oil (See Fig.8for location ofdrainhole andlevel plug).
Check tightnessof mounting boltsand electrical connections.
Monthly: Check oil levelin worm gear box.Oillevel shouldbe maintained tothe loweredgeofthe level plug hole
with the winch intheupright position as shown in Fig.8.
After 10hours ofwinching or annually: Change WormGearbox oil. Check tightnessof mounting boltsand
electrical connections.
Wormbox Gearbox:The winch is delivered from thefactory filled with the correct type and quantityofoil.
Changethe oilinthegearbox atleastonce ayear.Theoil specification recommended is BP MULTIGEAR FE
85/140 or equivalent,usingapproximately 3/4litre (0.2 U.S.gal).
LUBRICATION
The spur andwormgearboxesare self containedand individually lubricated. The spur gearboxis factory filled for
life with BPEnergrease FGLwhich is suitablefor mostclimates.Inextreme climates, (below 13°C or above 43°C)
contactSuperwinch for advice.
CLIMATE TEMPERATURE GEARBOX OIL
Arctic -13°C to 15°C SAE 90 Oil
(8°Fto59°F)
Temperate -16°C to 29°C SAE 85/140 Oil
(3°Fto85°F)
Tropical 19°C to43°C SAE 140 Oil
66°Fto100°F)
NOTE: EP(Extreme Pressure) additives can damage copper based alloys like phosphorbronzeused for the
worm gear and we do not recommend their use in the wormgearbox.Ifany doubtexists,consultyour lubricant
supplier’stechnicaldepartment.
The drum bearings and splined drumclutch are lubricated with molydisulphide loaded bearing grease.
0
8
RUNNING IN, MAINTENANCE AND REPAIRS 08-1
Fig. 8

OPERATIONTROUBLESHOOTING
Condition Possible Cause Correction
Low line pull Pump pressure output insufficient Referto “HydraulicInstallation” section.
Hydraulic hosetoo long orbore size Referto “HydraulicInstallation” section.
insufficient in size
Drum will notrotate under Load greaterthan rated capacity Referto Specifications pagefor line pull rating.
load
Winch runs too slow Motorworn out Replace motor.
Cable drum willnot Damagedfreespool mechanism See yourSuperwinchDistributor.
freespool
Oilleakagearounddrum Damageddrumseals Replace drum seals.
flange
Oilleakagearoundmotor Seals/ gasketsdamaged Replace all seals/gaskets.
orwormbox
Excessivenoise Lowoil level Check oil level, addoil if necessary.
Motor runs butdrumdoes Freespoolnot engaged Check engagement of freespool mechanism.
not turn
09
HYDRAULIC SYSTEMTROUBLESHOOTING
09-1

ACCESSORIES
OVERVIEW
Accessoriesmentionedinthismanualand recommended foruse with your winch include:
Pulley Block with4000 kg capacity Tow Hooks
Part No. 256009 Part No. 1510
Winch Accessory Kit CableTensioner
Part No.0505Part No. 5605 (Not8569)
RollerFairlead (HeavyDuty) NylonSling3” x 8’with 30,000 lbsrating
Part No. 8584 (Not8569) Part No.2531
1
0
ACCESSORIES 10-1

This Manual’s Part No.is:
9332
Issue No.
4
Superwinch Ltd.,
Abbey Rise, Whitchurch Road, Tavistock, Devon.
Great Britain.
PL19 9DR
Tel: [phone]
Fax:[phone]
[e-mail]
SuperwinchInc.,
Winch Drive,Putnam,Connecticut06260
U.S.A.
Tel: [phone]
Fax: [phone]