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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
b
c
Figure 16
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 per-
manently 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.
6. EQUIPPING THE WINCH WITH A
ROLLER FAIRLEAD will substantially
reduce wear on the wire rope
during angle pulls (Figure 17).
The rollers eliminate heavy rub-
bing and abrasion to the wire rope.
Figure 17
14
M A I N T E N A N C E
A N D R E P A I R S
Periodically check tightness of
mounting bolts and electrical con-
nections. Remove any dirt or corro-
sion 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.
LUBRICATION
The gearbox and drum bearing are
permanently lubricated with a high
performance gear lube. If relubrica-
tion is necessary (after repair or
disassembly) only use Shell Alvenia
EP2 or equivalent.
REPLACING THE WIRE ROPE
Figure 18
Never substitute a heavier or lighter
wire rope. Never use rope made of
any material other than wire.
Always replace damaged wire
rope with manufacturer's identi-
cal replacement part (see
Replacement Parts list). Pass attach-
ing end of wire rope through the
fairlead (if equipped) and attach it
to the drum. When inserting the
wire rope into the drum, insert it
into the correct end of the hole
provided (Figure 18). Tighten the
set screw securely.
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 fixed object at
the top of a slight incline, then
winch the vehicle up the incline.
BRAKE OPERATION
Your S Series winch has a wrap
spring brake that stops and holds
loads up to 50
rated capacity on
%
the first layer of wire rope closest
to drum.
Each additional layer of wire rope
reduces brake capacity approxi-
mately 10%. When powering the
winch in, the brake is disengaged
and does not become activated
until the motor is turned off and
the load tries to pull the wire rope
off the drum. When the winch is
powered out, as in releasing a load,
the brake is engaged and the motor
must over power the brake drag to
rotate the drum. Therefore, it is
normal for the winch to operate
faster in one direction than the
other. The brake is designed for the
wire rope to be used in the under-
wind position only. DO NOT OVER-
WIND. Powering against the brake
will cause heat to build up in the
drum and may transfer heat to the
wire rope (Figure 19). DO NOT
POWER OUT FOR MORE THAN 50
FEET (15.2m) OR 2 MINUTES.
The drum and
wire rope may
get very hot.
When wire rope is removed from
the drum, as in bringing the hook
to the load, the freewheel feature
of the winch should be used.
HOT!
Figure 19
15
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