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7. Equipping the winch with a roller
fairlead (Part No. 2539) will sub-
stantially reduce wear on the wire
rope during angle pulls. The
rollers eliminate heavy rubbing
and abrasion to the wire rope.
M A I N T E N A N C E
After the first 10 hours of opera-
tion: Change Worm Gearbox oil (see
Figure 14 for location of drain hole
and level plug). Check tightness of
mounting bolts and electrical con-
nections.
Monthly: Check tightness of all
electrical connections and remove
any dirt or corrosion that may
have accumulated. Check oil level
in worm gearbox. Oil level should
be maintained to the lower edge
of the plug hole with the winch in
the upright position as shown in
Figure 14.
After 50 hours of winching or annu-
ally: Change Worm Gearbox oil.
L U B R I C A T I O N
The spur and worm gear boxes are
self contained and individually lubri-
cated. The spur gearbox is factory
filled for life with BP Energrease
FGL which is suitable for the majori-
ty of climates. In extreme climates,
contact Superwinch for advice.
Climate
Temperature
Arctic
5º to 59º F
Temperate
32º to 86º F
Tropical
68º to 122º F
*Available from Superwinch
12
Level Plug
Drain Plug
Figure 14
Note: EP (Extreme Pressure) addi-
tives can damage copper based
alloys like phosphor bronze used for
the worm gear and we do not rec-
ommend their use in the worm gear
box. If any doubt exists, consult
your lubricant supplier's technical
department. The drum bearings and
splined drum clutch are lubricated
with polydisulphide loaded bearing
grease.
REPLACING THE WIRE ROPE
Never substitute a heavier or lighter
wire rope. Never use rope made of
any material other than wire.
Always replace damaged wire rope
with the manufacturer's identical
replacement part (see Replacement
Parts list). Any substitution must be
IDENTICAL in strength, quality, lay
and stranding. Pass attaching end of
wire rope through the hawse and
attach into the drum.
It is important that the wire rope be
wound tightly on the drum. A good
way to do this is to attach the wire
rope hook to a fixed object at the
top of a slight incline, then winch
the vehicle up the incline.
Spur Gearbox
Worm Gearbox
BP to Energrease FGL*
SAE 90 oil
BP to Energrease FGL*
SAE 85/140 oil
BP to Energrease FGL*
SAE 140 oil
R E P L A C E M E N T
P A R T S L I S T
Reference
Number
Description
1
Wormbox Assembly (includes 2,3,7)
2
Oil Seal
3
Plug
4
Wormset
5
Needle/Roller Thrust Bearing
6
Needle Bearing
7
Thrust Bearing
8
Thrust Washer
9
Location Plug
10
Oil Seal
11
O-Ring
12
Bearing Carrier
13
Spring Pin
14
Clutch Member
15
Retaining Ring
16
O-Ring
17
Clutch Assembly (includes 18, 19, 20, 21, 22, 23)
18
Clutch Shaft
19
Operating Lever
20
O-Ring
21
Spring Pin
22
Ball
23
Spring
24
Support Housing (includes 25)
25
Flanged Bearing
26
Rope Drum Assembly 3" (includes 27)
27
Socket Set Screw
28
Gear Housing
29
Cover
30
Gasket
31
Gear Motor 27T (2404)
Gear Motor 32T (2405)
32
Gear Intermediate 64/20T (2404)
Gear Intermediate 59/20T (2405)
33
Gear, Wormshaft 46T
34
Retaining Ring
35
Retaining Ring
36
Spacer
37
Key
38
Ball Bearing
39
Brake Shoe
40
Brake Spring
41
Motor Cover
42
Gasket
43
M8 Lock Washer
44
Screw M5 x 50
45
Motor 12 Volt (2404)
Motor 24 Volt (2405)
Part Number
Qty
85-90170
1
4-22-5572103
1
4-29-224
2
85-95019
1
7721
1
4-12-25322013
1
4-07-2542203
1
4-03-2542203
2
7667
1
4-22-2535073
1
4-21-6543
1
7654
1
4-56-401003
1
7659
1
4-24-4053183
1
4-21-7813
1
85-90174
1
7676
1
7673
1
4-22-6423
1
4-56-602603
1
4-54-79324
1
4-31-7629510223 1
85-90138
1
7653
2
9108
1
4-40-081003
1
85-90394
1
7649
1
7689
1
7663
1
85-54008
1
85-90172
1
85-90171
1
7666
1
4-24-19227103
1
4-26-1618123
1
7686
1
7764
1
94-23079-05
1
317
1
320
1
7683
1
7689
1
4-51-0823
1
7691
1
7682-I
1
7694-I
1
13
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