Superwinch Husky series User manual

Owner’sManual/FittingInstructions
Kit Nos. 8514&8515
ELECTRICALLY
POWERED
HUSKYWINCH

Owner’sManual/FittingInstructions
Kit Nos.
8514&8515
Theseinstructionscoverkitsfrom
16/07/1997
01 INTRODUCTION
02 GENERALSPECIFICATIONDATA
INTERMITTENTDUTY
INSTALLATION
03 WINCH
04 ELECTRICAL
05 WIRE ROPE
COMMISSIONING AND USE
06 TIPSFOREXTENDING THE LIFEOF YOUR WINCH
07 FREESPOOL USE
REMOTECONTROL OPERATION
MAINTENANCE
08 RUNNINGIN,MAINTENANCE AND REPAIRS
LUBRICATION
09 TROUBLESHOOTING
MISCELLANEOUS
10 ACCESSORIES
For allyourrequirements please contact your Superwinch agent:
i

INTRODUCTION
INTRODUCTION
Pleasereadandunderstandthisowner’smanualbeforeinstallingyour Huskywinch.Your Huskywinchisaverypowerfulmachine.If used
unsafelyorimproperly,there isapossibility thatproperty damage orpersonal injurycan result.We have included severaluniquefeatures in the
Husky winchtominimize this possibility;however,your safety ultimately depends on yourcaution when usingthe product.
Correctinstallation of yourHuskywinch is a requirementforproper operation.
PleaseNote:TheSuperwinchHusky winchisdesignedfor totalreliabilityduringvehiclerecoveryoperations. Thiswinchisnotdesignedtobe
usedin hoisting applications and Superwinchdoes notwarrant it suitable forsuch use.
Superwinchreserve therighttoalter modelspecifications without prior notice.
PLEASE RETAIN THIS 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.
USAGE OF WINCH
This winch is designedfor useinapplications suchas:
*Pulling*Hauling*Lifting (Vehicle Recovery ONLY) *and otherassociateduses.
POISONOUS SUBSTANCES
Many liquidsandother substancesusedshouldunder nocircumstancesbeconsumed,andshouldbe kept awayfromopenwounds.These
substancesinclude(amongothers)hydraulic oil.
SYNTHETIC RUBBER
Many ‘O’ ring seals, flexiblepipes and similar items, when subjectedtofire or heat canbecome highlycorrosive. Handlewithseamless industrial
gloves only.Shouldskincontact occur, removecontaminatedclothing immediatelyandobtain medicalassistancewithoutdelay.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.
WINCHING TECHNIQUES
Before usingyour winchit isveryimportantthatyouread thebookletsenttoyouwithyour winch entitledthe‘HandbookofWinchingTechniques
forVehicle Recovery’.Pleasereadand understandthis handbook before using yourSuperwinch and it’saccessories.Ithasbeen suppliedwith
yourwinchto encouragesafe operation-ifusedunsafelyorimproperly,there isa possibilitythatpropertydamage or personalinjury canresult,
since yoursafety ultimately dependsonyour cautionwhen using these products.
01
01-1 INTRODUCTION
SUPERWINCH winches are not to be usedto lift,support orotherwisetransport personnel.Any such useshall beconsideredto
invalidate the warranty andSuperwinchshall not be responsible for any claims arising from such use.

GENERALSPECIFICATION DATA
WINCH
Type ................................................ Husky
Gear Reduction .............................. Wormwheel
Gear Ratio ...................................... 294:1(12v)& 229:1(24v)
Drum ............................................... Fabricatedsteelrunningincopolymer maintenance freebearingswithspringloadedbrakestoprevent
overrun when pullingout therope.
Braking ............................................ Theirreversibleactionof the worm andwormgearprovides forsubstantialbraking action.
Freespool ........................................ Operated by an easyactionlever which disengages thegearbox to allowthe wire rope to bepulledout
without usingelectricpower.Aspringloadeddragmechanismreducesbacklash andsnarlingwhen
pullingout thewire rope.
Control Solenoids(relays) .............. Boxedpair of solenoids canbe mounted directon winch orremotely asrequired.
Remote Switch ............................... 3.5m handheldpendantswitch assembly.
ModelDesignation........................... Husky Husky
Part No ........................................... 8514 8515
ElectricMotor .................................. 12v1.4 Kw (1.9hp) 24v 1.6 Kw (2.1 hp)
RatedLinePullBottom Layer ......... 37.8 kN (8500 lbs) 37.8kN(8500lbs)
LineSpeed1st Layer (No Load) ..... 6.9m/min (22ft/min) 6.9 m/min (22 ft/min)
Rope Diameter (Recommended) .... 9 mm 9 mm
Rope Length ................................... 30 m (100 ft) 30m (100ft)
Drum Diameter ............................... 76.2 mm(3”) 76.2mm (3”)
Current Draw atRatedLine Pull .... 340 A 180A
Weight ............................................. 38 kg(84 lbs) 38kg (84lbs)
8514
Fig. 1
0
2
GENERALSPECIFICATION DATA 02-1
0100 200 300 400
0
10
20
30
40
MOTORCURRENT(Amps)
LINE PULL (kN)
0100 200 300 400
0
2
4
6
8
10
Thousands
MOTORCURRENT(Amps)
LINE PULL (lbf)
010 20 30 40
0
2
4
6
8
LINEPULL (kN)
L IN E SP E ED ( m/ m i n)
0 2 4 6 8 10
0
5
10
15
20
25
Thousands
LINEPULL (lbf)
LINE SPEED (ft/min)

GENERALSPECIFICATION DATA
8515
Fig. 2
INTERMITTENT DUTY
Allelectricwinchesofthissizeare ratedfor intermittentusebecauseoftheelectricmotor efficiencyand the electricpower availablefrom the
vehicle battery and alternator.This means thatthewinch mustonly be usedfor short periods oftimethenallowed to cool down.
If themotorbecomes uncomfortably hot to touch, stop winching and alow the motor tocool.
If thewinch motorstalls do not continue to apply power to the winch.
Theperformanceratingof allelectricwinchesisbasedon thefirstlayer ofropeonthedrum.Thewinchpullingcapacitydecreasesaseach
successivelayerof rope wraps ontothe drum.
Cable Hawse Motor
Drum Fairlead Worm Cover
Gearbox
Drum
Clutch
Lever
Motor
Support Housing Spur Gearbox
Fig. 3
02
02-2 GENERAL SPECIFICATION DATA
050 100 150 200
0
10
20
30
40
MOTORCURRENT(Amps)
LINE PULL (kN)
050 100 150 200
0
2
4
6
8
10
Thousands
MOTORCURRENT(Amps)
LINE PULL (lbf)
010 20 30 40
0
2
4
6
8
LINEPULL (kN)
L IN E S P E E D ( m/ mi n )
0 2 4 6 8 10
0
5
10
15
20
25
Thousands
LINEPULL (lbf)
LINE SPEED (ft/min)

WINCH INSTALLATION
WINCH INSTALLATION
The kitmust be usedinconjunctionwith theincluded wiring kit. Before commencinginstallationidentifythe contentsof the following:
Contents, Cardboard Container
Item Qty PARTNo. Description
1 1 Husky Winch Assembly
2 1 9134 /207 Power Cable 0.7m Red
3 1 9134 /307 Power Cable 0.7m Blue
4 1 9134 /407 Power Cable 0.7m Yellow
5 1 8903 (12v) Control Box
1 8904 (24v) Control Box
6 1 PlasticBag
7 1 8857 Remote Control, 6m
Contents, Bag 1
Item Qty PARTNo. Description
8 2 PlasticBags
9 1 8057 Handsaver Bar
10 1 5-001-078 Owners Manual
11 1 5-010-080 WinchingTechniques
12 1 CertificateofConformity
Contents, Bag 2
Item Qty PARTNo. Description
13 4 7804 Spacer
14 4 4-33-1005032 Bolt, M10 x 50mm
15 4 4-36-0803522 CapHeadSetScrewM8 x35mm
16 1 351 Bolt, 5/16”UNF x 3/4”
17 4 4-50-1023 Washer,Plain, M10
18 4 4-50-0823 Washer,Plain, M8
19 5 4-51-0823 Washer,Spring,M8
20 4 4-51-1023 Washer,Spring,M10
Contents, Bag 3
Item Qty PARTNo. Description
21 1 4-122-1083 HexagonSocket SetWrench1/4”
22 1 4-122-2053 HexagonSocket SetWrench4mm
23 1 4-122-2073 HexagonSocket SetWrench6mm
0
3
WINCH INSTALLATION 03-1

WINCHINSTALLATION
Fig. 4
WINCH INSTALLATION
1. Alldimensions are in mm.
2. Winch mountingcanbeviaa winchmountplate (SeeSuperwinchAccessories).
3. Thewinch (together with it’smounting plateif fitted) must be securelyboltedontoamountingsurfacethat isflatwithin0.5mmandsufficiently
stiffto preventflexing.
4. Allfourwinchmounting holesmarked ‘A’mustbe used.
5. Although thewinch may bemountedineither‘overwound’ or ‘underwound’positions, ‘underwound’isrecommended.
6. Mountingboltsmustbe8.8 gradehightensile steel.
03
03-2 WINCH INSTALLATION

ELECTRICALINSTALLATION
ELECTRICALINSTALLATION
Precautions:Leave allcableconnectionstothebatteryterminalsunconnecteduntilall wiringhas beeninstalledand checkedthoroughly
for correctconnections, asdamage to the vehicle wiring circuit couldbecausedby wrong connectiononce thebattery is connected. All
wiringshould be bound and securely fastenedtoadjacentstructureusing the cabletiessupplied where necessary.
Becauseofthehighcurrent draw inherentinallelectricwinches it isrecommendedthattheengineofyour vehicleiskeptrunningduringthe
winching operationtoensure thatthebattery is not drained forvehicle restarting.
Be sure that thebatteryis always fullycharged and maintained.
Theperformance ofanelectric winch is directlydependant onthe quality and capacityofthebattery andalternator.Ifthewinchis in heavy use,
anauxiliary battery and heavy duty alternatorwith abatteryisolatorare recommended.
Itis essential to use thecontrol solenoids suppied with yourwinchso that burn outofthe electricsystem does notoccur.
Warning: Do not, under any circumstances,wire the winch direct from the vehiclebattery.Do not connecteitherwinch orsolenoidsto
240 volta.c.house currentassolenoid burn outorfatal shock may occur.
Note:Forsafetyreasons,we recommendtheinstallationof Isolator switchPartNo. 8370, which canbeusedto cut powertothewinch.
The switch shouldbe wired in linewith thepower lead from the battery positiveterminal(seewiring diagrams). It should bemountedin
a position where powercan be switched off in an emergency.
The winch operates onstandard automotive 12or24volt directcurrent.
Step(1)Disconnectthe battery ‘negative’terminal connection.
Step (2) Remove thesolenoid cover.
Caution: When attachingwires to themotor terminalsand solenoids,hold theinner nut whentightening theouternut. Do not allow the
motor or solenoid terminals torotate causinginternal wire breakage. See pages24 and25 forrelevant diagrams.
Step(3)Remove motorcover.Check motorterminals againstwiringdiagram for identification.
Step (4) Attach lead wiresasshowninwiringdiagram(Fig. 5). Pleasenotethat lead wiresare notsuppliedfor connection tothe battery+veand
-ve.Thisisbecausetheseleadscan be ofverydifferentlengths dependanton the variousvehicle/ mountconfigurations.The wire usedto power
the winchoffersresistancetotheflowofelectriccurrent.Thelonger thewirethemoretheresistance.Whenmoreresistancetocurrentflow
occurs, less currentisavailable atthe motorcausing itto runslowerand have lesspower.
Fig. 5
0
4
ELECTRICALINSTALLATION 04-1

ELECTRICALINSTALLATION
Fig. 6
Todetermine thesize wirerequired to operate yourwinchyoumust firstcalculatethe resisitance from thefollowingformula:
Ω= 2000 = ohms/ 1,000ft
DxI
where: Ω=Totalresistance inohms /1,000 ft
D = Totaldistancethe electriccurrent musttravel,i.e. distancefrom battery-ve terminal to motoradded to distance frombattery
+vetosolenoids.
I = 340 (Husky 5254) or 180 (Husky 5255)
Nowselectthe wire gauge from thetableopposite.
Note that the connectors must be to suit8mm studs and theselected wire gauge.
Wire Gauge Resistance
(AWG) (Ω)
4/0 0.04901
3/0 0.06180
2/0 0.07793
1/0 0.09827
10.1239
2 0.1563
4 0.2485
6 0.3951
8 0.6282
10 0.9989
04
04-02 ELECTRICALINSTALLATION

WIREROPEINSTALLATION
WIRE ROPE SPECIFICATION
The rope mustbeofgood quality,haveasteel core andmeetthefollowingspecifications:
ModelDesignation .......................... Husky
Part No. .......................................... 8514 &8515
Drum Diameter ............................... 76.2 mm
Calculated Min.Breaking Load ...... 51.0 kN (11464 lbf)
Tensile Grade ................................. 1770 N/mm2
Rope Diameter ............................... 9.0mm
Max.RopeLength .......................... 30 m
WIRE ROPE INSTALLATION
Whenthe winch issuppliedfromthefactorywithoutwire ropefitted, youshouldinstalltheropeinthefollowingsequence. Theinstallationofa
rope isasimple procedure. It is agood ideatohave someoneto help you withthis. First make sure theremote control is unpluggedtoprevent
unauthorised use when yourworking around theropestorage drum.
1. Unwindthe cable by rolling it along thegroundwith the taperedendnearesttothewinch.Never windthe cablestraight onto the drum from
a coil(Fig.8).
2. Move theclutch handle to the‘disengaged’position as shown in Fig. 7.
3. Insertthetaperedendof the ropethroughthefairleadandontothedrum.In theoverwound position,passthe ropestraightintotherope
fixinghole.Intheunderwoundposition,pass theropeundertheropedrumandthreadthe ropeintothefixingholefromdrum.Fixtheend
ofthe ropewith thesetscrew.
4. Movetheclutch handle tothe‘engage’position(Fig. 7). Connect theremote control. Iftheleverdoes notslideeasilyinto engagement,it may
benecessaryto momentarily operate thecontrol switchthenrelease to the off position.
5. Carefully runthe winchinthe ‘winch in’direction.Keeping tensionon thecablespool5 or 6wraps ofcable neatly onto thedrum.
6. Applymoderate tension (approx.1500 kg)to the rope.Thismaybeachievedbyanchoring the ropehook(witha sling)to atreeand winching
the vehicletowards the treewithbrakesapplied lightly.Take care to ensurethelayers areneatly wrapped. This willminimise damage to the
lowerlayers ofrope when aload is applied.Usethe handsaverbartoguide theropethe lastfewfeet onto thedrum.
Note;Wherea wirerope isnotsupplied, or whenreplacing awire rope, always use aSuperwinch recommendedwire rope.
PULLINGTHE WIRE ROPEOUT
Move theclutchhandletothe‘disengage’position.Pullout theropeandsecuretoanchororload,checkthatthere areatleast5turnsleft on
the drum.
Re-engagethe drumbymovingtheclutch handletothe‘engage’position(Fig. 7). If thehandledoesnotslideeasilyintoengagement, itmay be
necessary tomomentarilyoperate thecontrolswitchthenrelease to theoff position.
Fig. 7 Fig. 8
0
5
WIRE ROPE INSTALLATION 05-1