O W N E R ’ S M A N U A LINSTALLATION • OPERATION • MAINTENANCESAFETY PRECAUTIONS • REPLACEMENT PARTS

READ AND UNDERSTAND THIS MANUALBEFORE INSTALLATION AND OPERATION OF

YOUR SUPERWINCH PRODUCT.

61-12880 Rev A 11/08/13

DC POWER DRIVES

Superwinch, LLC.359 Lake RoadDayville, CT 06241 USAtel: 1.800.323.2031fax: 1.860.963.0811sales@superwinch.comwww.superwinch.com

Superwinch, LTD.Union Mine RoadPitts CleaveTavistock, Devon UK PL19 ONS tel: +44 (0) 1822 614101fax: +44 (0) 1822 615204sales@superwinch.netwww.superwinch.com

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Thank you for purchasing a Superwinch product. It has been designed andmanufactured to provide years of trouble-free operation. Please read andunderstand this Owner's Manual before using your Power Drive. If usedunsafely or improperly, there is a possibility that property damage or per-sonal injury can result. Your safety ultimately depends on your cautionwhen using the product. Correct installation is a requirement for correctoperation. Pay particular attention to the Safety and Installation sections ofthis manual.

Superwinch reserves the right to alter model specifications without priornotice. Superwinch, through its continuous improvement policy reserves theright to improve any product through changes in design or materials as itmay deem desirable without being obligated to incorporate such changes inproducts of previous manufacture.

PLEASE KEEP THIS OWNER'S MANUAL WITH THE UNIT.

These instructions are designed to assist skilled technicians in the efficientinstallation of the Power Drive, using the appropriate trade tools.

I N T R O D U C T I O N

Several models of Power Drives areavailable to fit your needs. Optionsinclude different reduction ratios, DC motor.

Each Power Drive is equipped with apermanent magnet motor and isdesigned for intermittent use only.This means that the Power Drivemust be used for only short periodsof time and allowed to cool down.

GENERAL DESCRIPTION

IF THE MOTOR BECOMES UNCOMFORTABLY HOT TO TOUCH,STOP OPERATION AND ALLOW IT TO COOL.

IF THE MOTOR STALLS, DO NOT CONTINUE TO APPLYPOWER TO THE UNIT.

Figure 1: Power Drive

I N T R O D U C T I O N

Gearbox Type Right AngleGear Reduction Worm and WheelBraking Inherent-See Warning in Safety SectionMounting Three point bulkhead, requiring three

5/16-18 UNC Grade 5 or better boltsOutput Shaft(s) 3/4 OD with 5/16 through hole and

3/16 keyway

S P E C I F I C AT I O N S

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D I M E N S I O N SFigure 2: Power Drive Dimensions

Table 1: Specifications

OHL = Overhung Load

Weight Motor PowerPower Drive #'s Ratio (Lbs.) Voltage (hp)

719527, 719520 90:1 10.5 12V DC 1.3719627 90:1 11.5 12V DC 1.8

719537 90:1 10.5 24V DC 1.3719637, 719630 90:1 11.5 24V DC 1.8716527 60:1 10.5 12V DC 1.3716627 60:1 11.5 12V DC 1.8

716537 60:1 10.5 24V DC 1.3716727 60:1 12.3 12V DC 2.1

Power Drive #'s "L" Power Drive #'s "L"719527, 719537, 716527 719630 11.6 11.0

719627, 719637, 716627 11.4

S P E C I F I C AT I O N S

L

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2790

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4 2

45 2

40 5

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300

320

G E N E R A L S A F E T Y I N F O R M AT I O N

1. NEVER CONNECT YOUR POWER DRIVE TO ANY POWER SOURCEOTHER THAN THAT SPECIFIED ON THE MOTOR. THIS CAN CAUSEDAMAGE TO THE MOTOR AND POSSIBLY FATAL ELECTRICAL SHOCK.

2. ALWAYS DISCONNECT THE UNIT FROM ITS POWER SUPPLY PRIOR TO PER-FORMING ANY MAINTENANCE OR REPAIR.

3. NO POWER DRIVE IS TO BE USED IN A CORROSIVE OR EXPOLSIVE ENVIRONMENT.

4. NEVER OBSCURE THE WARNING LABELS ON YOUR UNIT.5. DO NOT OPERATE THE POWER DRIVE WHEN UNDER THE INFLUENCE OF

DRUGS, ALCOHOL OR MEDICATION.6. POWER DRIVES ARE INHERENTLY SELF-LOCKING, MEANING THAT UNDER

MOST CIRCUMSTANCES A TORQUE OF LESS THAN 3000 in-lb APPLIED TOTHE OUTPUT SHAFT WILL NOT CAUSE THE SHAFT TO ROTATE. HOWEV-ER, VIBRATION OR ROTATION OF THE INPUT SHAFT COULD CAUSE THEBOX TO LOSE ITS ABILITY TO RESIST THIS TORQUE, RESULTING IN A RUN-AWAY CONDITION. FOR THIS REASON, POWER DRIVES SHOULD NOTBE USED AS A BRAKE IN APPLICATIONS WHERE PERSONAL INJURYOR PROPERTY DAMAGE COULD RESULT FROM A RUN-AWAY CONDITION.

7. DO NOT MACHINE OR WELD ANY PART OF THE POWER DRIVE. SUCHALTERATIONS MAY WEAKEN THE STRUCTURAL INTEGRITY OF THE UNITAND WILL VOID YOUR WARRANTY.

I N S TA L L AT I O N

MOUNTINGThree 5/16" UNC x 1/2" deep mounting points are provided on the mainoutput side of the gearbox in order to facilitate bulkhead mounting. Thebulkhead should be drilled in accordance with the dimensions in Figure 3.Because of the torque involved, it is important that the mountings aresecure, it is recommended that the mounting bolts be of Grade 5 or higherand torqued to 65-75 in-lb.

All three mounting holes must be used. Use only the threaded holes provided,do not drill and tap new hole(s). Do not weld the gearbox or any parts of theunit.

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6

COUPLINGYour Power Drive has an output shaft for coupling to a load.Figure 2 on page 3 shows the specifications on the shaft configuration.Care should be taken to ensure that any tube that is rigidly attached to thegearbox is as straight as possible to remove the possibility of an oscillatingload.OVERHUNG LOADThe table below shows the maximum allowable overhung loads that may beapplied to either output shaft at a distance P. P is measured from the oilseal face to the location of the load (see Figure 2).

P E R F O R M A N C EI N S TA L L AT I O N ( C O N T. )

P (in) Max. Overhung Load (Lbs.) P (in) Max. Overhung Load (Lbs.)

0.75 900 3.75 270

1.75 504 4.75 216

SPLASH COVERA Splash Cover and 2 mounting screws are provided with each unit. If youhave a manual override unit, remove the round black plastic cover from thegearbox (Figure 1) and install it into the access hole in the splash cover.Once the gearbox installation is complete, place the splash cover over theunit and install the two self-tapping screws into the gearbox housing.

E L E C T R I C A L C O N N E C T I O N – D C U N I T S

This section applies to the electrical connections of the DC PowerDrives only.

Caution: When attaching wires to the motor terminals, hold the innernut when tightening the outer nut. Do not allow terminals to rotate caus-ing internal wire breakage.

Caution: Leave all cable connections to the battery terminals uncon-nected until all wiring has been installed and checked thoroughly for cor-rect connections. All wiring should be bound and securely fastened to theadjacent structure using cable ties where necessary.

This unit operates on standard automotive direct current. Proper wire sizeand length are critical for the unit to perform properly. See thePerformance section for further information.

1.03

1.03

1.03

2.50

1 HOLE 7/8

3 HOLES 3/8

Figure 3: Mount Hole Locations (Inches)

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E L E C T R I C A L C O N N E C T I O N – D C U N I T S, (.CONT.)

This section applies to the electrical connections of the DC PowerDrives only. CONNECTIONSElectrical connection is made via the two 1/4-20 UNC studs on the end of themotor (see Figure 2 on page 3). Hold the inner nut with a wrench when tightening the outer nut. Torgue the outer nut to 21-26 lb. in.Step (1) Disconnect the battery "negative" terminal connection.

Step (2) Check motor terminals against Figure 2 for identification.

Step (3) Connect stud 1 to the positive terminal and stud 2 to the negativeterminal. This will cause the gearbox output shaft to rotate in a clockwisedirection as viewed from the mounting side. Reversing the connections willreverse the direction of rotation.

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P O W E R D R I V E A S S E M B LY

Fig

ure

6:Po

wer

Dri

veA

ssem

bly

⁄

1

2

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9

10

9

R E P L A C E M E N T PA R T S

1 1 12V Motor (Power Drive #'s 719527 90-33319716527

1 1 12V Motor (Power Drive #'s 719627 90-33295716627 )

1 1 24V Motor (Power Drive #'s 719537 90-33320716537)

1 1 24V Motor (Power Drive #’s 719637 90-33318719630, 719632)

2 2 Flanged Nuts, 1/4 -20 90-23149-02

8 1 Splash Cover (Power Drive #'s 60-33291-01719537, 716537)

8 1 Splash Cover (Power Drive # 60-33302-01719630

8 1 Splash Cover with Screws 61-17315(Power Drive #'s 716527,716627, 716727, 719527, 719621, 719627, 719631, 719637, 719727)

9 2 Self-tapping Cover Screw 60-23039-1210 3 5/16 UNC Grade 5 or Better Not Supplied

Mounting Bolts and Washers

1 1 12V Motor (Power Drive #’s 716727 90-33294719727)

M A I N T E N A N C E A N D R E PA I R

Periodically check the tightness of mounting bolts and electrical connections.Remove any dirt or corrosion that may have accumulated on the electricalconnections.

Repairs should be done by Authorized Superwinch Repair Centers ONLY. Donot attempt to disassemble the gearbox. Disassembly will void your warranty.

LUBRICATIONThe gearbox is lubricated and sealed for life. If re-lubrication is necessary(following repair or disassembly), the gearbox should be filled with 5 ouncesof Mobil SHC 630 lubricant or equivalent.

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