Superatv Ewp3500a User manual

EWP3500A Winch

OPERATING MANUAL

Winch

Control BoxFairlead

Wiring

Wireless

Remote Control

Clevis Hook

and Pin

Mounting Plate

Rocker Switch

Hardware

Ba󰀪e Ring

Solenoid

Controls Splitter Hand Strap

Read instructions and view illustrations before beginning.

2753 Michigan Road • Madison, Indiana 47250 • 855-743-3427

Thank You

For Choosing

Need help with your installation?

www.superatv.com

8:00am - 9:00pm EST M-Th

8:00am - 7:00pm EST Friday

9:00am - 2:00pm EST Saturday

sales@superatv.com

1-855-743-3427

EWP3500A 2

INTRODUCTION:

Congratulations on your purchase of a high quality winch designed and built to strict

specications. Proper use and maintenance will ensure years of reliable, satisfying

service.

A winch can develop tremendous pulling forces. If winch is used improperly, or in an

unsafe manner, personal injury, death, and/or property damage can occur. Throughout

this operating manual CAUTION, WARNING, and DANGER symbols are present. Pay

particular attention to notes preceded by these symbols as they are written for your safety.

User is responsible for safe operation of this device.

WARNING: Read, study, and follow all instructions before operating winch.

Failure to heed these instructions may result in personal injury, death, and/or

property damage.

Indicates a potentially hazardous situation, which if not avoided,

may result in minor or moderate injury. This symbol is also used

to alert user against unsafe practices.

CAUTION

Indicates a potentially hazardous situation, which if not avoided,

may result in death or serious injury.

WARNING

RECOMMENDED WINCH ACCESSORIES (not included):

Gloves: Protect hands when handling Synthetic Rope.

Anchor Strap/Chain: 5,000 lbs. - 10,000 lbs. high tensile strength strap.

Blanket: Place on Synthetic Rope to absorb energy in event of a failure.

Liability Statement

SuperATV’s®products are designed to best fit user’s ATV/UTV under stock conditions. Adding, modifying, or fabricating any factory or aftermarket parts will void any warranty

provided by SuperATV®and is not recommended. SuperATV’s® products could interfere with other aftermarket accessories. If user has aftermarket products on machine, contact

SuperATV®to verify that they will work together.

Although SuperATV®has thousands of satisfied customers, user should be aware that installing lift kits, long travel, or suspension kits, tires, etc. will change the ride of machine

and may increase maintenance and part wear. Operating any off-road machine while, or after, consuming alcohol and/or drugs increases risk of bodily harm or death. No

warranty or representation is made as to this product’s ability to protect user from severe injury or death. SuperATV®urges operators and occupants to wear a helmet and

appropriate riding gear at all times.

By purchasing and installing SuperATV®products, user agrees that should damages occur, SuperATV®will not be held responsible for loss of time, use, labor fees, replacement

parts, or freight charges. SuperATV®, nor any 3rd party, will not be held responsible for any direct, indirect, incidental, special, or consequential damages that result from any

product purchased from SuperATV®. The total liability of seller to user for all damages, losses, and causes of action, if any, shall not exceed the total purchase price paid for the

product that gave rise to the claim.

SuperATV®will warranty only parts provided by SuperATV®. Any damage or problems with OEM housings, bearings, seals, or other manufacturers’ products will not be covered

by SuperATV®. SuperATV®parts and products are not warrantied if item was not installed properly, misused, or modified.

Installing, adding, modifying, or fabricating any factory or aftermarket product to your ATV/UTV may violate certain local, state, and federal laws. Be advised that laws vary

depending on town, city, county, state, etc. Use of certain products on public streets, roads, or highways may be in violation law. The Buyer is solely and exclusively legally and

personally responsible for any violation of the law by the installation or use of the product. You must abide by all local, state, and federal laws, including but not limited to vehicle

safety, traffic laws, and ordinances. It is your responsibility to know the laws and how they apply to you.

The Buyer is responsible to fully understand the capability and limitations of his/her vehicle according to manufacturer specifications, warnings and instructions and agrees to

hold SuperATV®harmless from any damage resulting from failure to adhere to such specifications, warnings and/ or instructions. The Buyer is also responsible to obey all

applicable federal, state, and local laws and ordinances when operating his/her vehicle while using this product, and the Buyer agrees to hold SuperATV®harmless from any

violation thereof.

EWP3500A 3

GETTING TO KNOW YOUR WINCH:

A winch is a powerful piece of machinery. For safe and condent operation, it is important

to understand basic winch operations and specications. See below for details on winch

components and usage. Practice using winch before an actual situation occurs.

Winch has been engineered with several patented technologies.

Motor: Motor is powered by a 12 volt battery. Motor provides power to Mechanic Gear

Mechanism which turns Winch Drum and winds Synthetic Rope.

Winch Drum: Cylinder on which Synthetic Rope is stored. Winch Drum feeds or winds

Synthetic Rope depending on Winch switch direction.

Synthetic Rope: Ø3/16” x 50’ long Synthetic Rope designed specically for a load

capacity of 3500lbs. and is looped at end to accept clevis hook pin. Synthetic Rope feeds

onto Winch Drum through Fairlead when in “under wind” position.

Fairlead: When operating Winch at an angle, Fairlead guides Synthetic Rope onto Winch

Drum and minimizes damage/abrasion from winch mount or bumper.

Mechanic Gear System: Converts Motor power into extreme pulling forces.

Braking System: Braking action is automatically applied to Winch Drum when Motor

is stopped and there is load on Synthetic Rope. A separate mechanical brake applies

braking action.

Control System: Winch can be controlled by using Power Cord/Switch Assembly or

through Remote Control.

Free Spooling Clutch: Allows user to manually disengage (“CLUTCH OUT”) Winch Drum

from Mechanic Gear System; free spool. Engaging clutch (“CLUTCH IN”) locks Winch into

Mechanic Gear System.

Solenoid: Power from vehicle battery ows through a weather-sealed switch before being

directed to Motor.

Rocker Switch: Power switch leads have a dual switch for powering in or powering out

Winch Drum. Rocker Switch allows user to stand clear of Synthetic Rope when Winch is

under load.

Wireless Remote Control: Allows user to operate Winch from 50’ away.

Mounting Plate: Plate that can mount to most at surfaces such as trailers, step

bumpers, truck beds, etc. Fairlead mounting holes included.

Pulley/Snatch Block (not included): Doubles pulling power of Winch or changes pulling

direction without damaging Synthetic Rope. When pulling over 70% of rated line pull, it is

recommended to use double line and snatch block.

EWP3500A 4

WINCH ASSEMBLY AND MOUNTING:

Winch is designed with a standard bolt pattern for its class. Di󰀨erent mounting kits are

available that utilize this pattern.

If installing supplied Mounting Plate, install to a at surface so Motor, Winch Drum, and

Gear Housing are properly aligned. Proper alignment allows for even distribution of full

rated loads.

1. Install supplied Fairlead to supplied Mounting Plate with (2) each M8 x 20mm Lg.

HHCS, M8 Flat Washers, M8 Lock Washers, and M8 Nuts.

2. Install Winch to Mounting Plate:

- Set Free Spooling Clutch to “CLUTCH OUT” and pull out a few inches of Synthetic

Rope.

- Feed Synthetic Rope through opening in front of Mounting Plate and through Fairlead.

3. Make electrical and component connections. Illustrations on following page.

4. Assemble Clevis Hook to Synthetic Rope: See following page.

- Remove Pin from Clevis Hook and connect Clevis Hook to Synthetic Rope.

- Reinstall Pin to Clevis Hook.

5. Install Hand Strap to Clevis Hook. See following page.

6. Install Ba󰀪e Ring to Synthetic Rope. See following page.

6. Check Winch Drum for proper rotation:

- Set Free Spooling Clutch to “CLUTCH OUT” and pull out some Synthetic Rope.

- Set Free Spooling Clutch to “CLUTCH IN” and press “OUT” button on Rocker Switch.

If properly installed, Winch Drum should be turning and releasing Synthetic Rope. If

Winch Drum is turning and collecting more Synthetic Rope, reverse leads on Motor.

Repeat and check rotation.

- Remove all jewelry and wear eye protection when making battery

connections. Batteries contain ammable and explosive gases.

Avoid leaning over battery.

CAUTION

Mounting Plate

Use hardware shown when installing Mounting Plate to Winch.

Universal mounting plate shown. Machine specic

mounting plates are available at www.SuperATV.com

(Winch Assembly and Mounting illustrations continue on following page)

EWP3500A 5

WINCH ASSEMBLY AND MOUNTING (continued):

Ba󰀪e Ring

install onto Synthetic Rope

and replace Lock

remove Lock

(tap with a hammer)

EWP3500A 6

Control Box

Rocker Switch

Solenoid

Controls Splitter

Connect

Connect Connect

Connect to Battery

Connect to Solenoid

See “Winch Key On Power”

WINCH WIRING: ensure no wires are pinched during installation and operation

To Battery POS, “+”

To Battery NEG, “-”

Solenoid

12V Switched Wire

Winch Key On Power

Make connection Connect to a switched 12V source;

(Ignition Key)

To Winch NEG, “-”

To Winch POS, “+”

Winch

Connect to Winch

DO NOT CONNECT DIRECTLY TO BATTERY

EWP3500A 7

WARNING - Do not exceed rated capacity shown in following table.

Layer Rated Line Pull lbs (kgs) Total Rope On Drum ft (m)

13500 (1588) 5.9 (1.8)

22789 (1265) 13.5 (4.1)

32319 (1052) 22.0 (6.7)

41984 (900) 31.2 (9.5)

51733 (786) 42.0 (12.8)

WARNING - Never cut, weld, or modify any part of Winch or Synthetic Rope.

WARNING - When under load, never step over or go near Synthetic Rope.

WARNING - A minimum of (5) wraps of Synthetic Rope around Winch Drum is

necessary for pulling and holding rated load.

WARNING - Keep yourself and others a safe distance and to a side when

Synthetic Rope is under tension.

WARNING - Synthetic Rope may break before Motor stalls. For heavy loads at or

near rated capacity, use a pulley block/snatch block to reduce load

on Synthetic Rope.

WARNING - Don’t move vehicle to pull a load (towing) on Synthetic Rope. This

can result in Synthetic Rope breakage.

WARNING - Avoid “shock loads” by using control switch intermittently to take up

slack in Synthetic Rope. “Shock loads” can exceed rated capacity for

Synthetic Rope and Winch Drum.

(Safety Precautions continue on following page)

SAFETY PRECAUTIONS:

Failure to heed these warnings and cautions may result in personal injury and/or property

damage.

load

WARNING - Do not use Winch to lift vertically or as a hoist.

Winch

WARNING - Do not use Winch to pull or

move people in any way.

EWP3500A 8

SAFETY PRECAUTIONS (continued):

WARNING- When re-spooling, ensure that Synthetic Rope spools in “under wind”

position with Synthetic Rope entering Winch Drum from bottom, not

top. To spool correctly, keep a slight load on Synthetic Rope while

pushing remote button to draw in Synthetic Rope. Walk toward Winch

while not allowing Synthetic Rope to slide through hands. Do not

let hands get within 12″ of Winch while re-spooling. Turn o󰀨 Winch

and repeat procedure until only a few feet of Synthetic Rope remain.

Disconnect Remote Control and nish spooling by hand; rotate Winch

Drum by hand with Clutch disengaged. Keep hands clear of Fairlead

and Winch Drum while Winch is under power.

WARNING- Never connect Synthetic Rope back onto itself.

Side cutaway view of Winch

Side Cutaway View Of Winch

Rope Exiting

From Under

Drum

(Safety Precautions continue on following page)

Hand Strap

- Use Hand Strap when handling Clevis Hook. Use gloves to protect

hands when handling Synthetic Rope. Never let Synthetic Rope slide

through bare hands.

CAUTION

EWP3500A 9

GENERAL TIPS FOR SAFE OPERATION:

• Winch is rated at 3,500 lbs capacity when spooling rst Synthetic Rope layer onto

Winch Drum. Overloading can damage components. For loads over 70% of rated line

pull, it is recommend to use a pulley block/snatch block to double rope line. When

doubling line, number of layers on Winch Drum is reduced and load on Synthetic Rope

is reduced by as much as 50%. Attach to frame or other load bearing component when

doubling line back to vehicle.

• To minimize battery drain and maximize power and speed of Winch, keep vehicle

engine running during winching. Battery may be drained if winch is used for a

considerable amount of time with engine o󰀨.

• Know all features before actual use. Become familiar with rigging techniques, sounds

made under various loads, way Synthetic Rope spools onto Winch Drum, etc. by

performing several test runs.

• Inspect all components, hardware, and electrical connections before each use. If

Synthetic Rope is frayed or damaged, replace immediately. Use only manufacturers

replacement rope. Replace or remove any component that appears to be damaged,

worn, or operating abnormally.

• Never connect Synthetic Rope back onto itself. Always use a snatch block, sling, or

chain of suitable strength.

• Pull only on parts of vehicle as specied by vehicle manufacturer.

• Use only attachments and/or adapters supplied by manufacturer.

• Test run Winch in (2) directions before winching.

SAFETY PRECAUTIONS (continued):

Pulley/Snatch Block Winch

Anchor point

on vehicle

Synthetic Rope

to sling/tree stap

and anchor point

- Never disengage Free Spooling Clutch when a load is on Winch.

CAUTION

- If Motor stalls, stop winching immediately. Electric winches

are designed for intermittent use. Do not use in constant duty

applications. Keep duration of winching pulls as short as possible: Do

not use for more than (1) minute when at or near rated load. If Motor

becomes hot to touch, stop winching immediately. Allow Motor to cool

before resuming.

CAUTION

WARNING- Apply blocks to wheels of vehicle when on an incline.

EWP3500A 10

RIGGING TECHNIQUES:

To absorb energy in event of Synthetic Rope

failure, place a blanket or jacket over Synthetic

Rope approximately 5ft - 6ft from Clevis Hook

before pulling a heavy load. Open vehicle hood

for more protection.

Do not winch from an acute angle. Synthetic Rope will pile up on one side of Winch Drum

causing damage to Synthetic Rope and Winch.

Short pulls from an angle can be used to straighten vehicle. Long pulls must be done with

Synthetic Rope at a 90° angle to winch/vehicle.

Winch

incorrect angle

Winch

correct angle

sling/tree strap

Locate a suitable anchor such as a strong tree

trunk or boulder. Always use a sling/tree strap

as an anchor point.

EWP3500A 11

OPERATING WINCH:

1. Take time to assess situation and thoroughly plan pull.

2. Set Free Spooling Clutch to “CLUTCH OUT” position.

3. Pull Synthetic Rope and attach to vehicle to be winched. Wear gloves and use Hand

Strap.

4. Secure Clevis Hook to anchor point: Sling, chain or snatch block. Do not attach Clevis

Hook back onto Synthetic Rope.

5. Set Free Spooling Clutch to “CLUTCH IN” position.

6. Start vehicle engine so that battery is being charged while winching.

7. Slowly winch in Synthetic Rope just enough to take up slack.

8. Inspect Synthetic Rope. Make sure there are minimum 5 wraps of Synthetic Rope

around Winch Drum.

9. To absorb energy in event of Synthetic Rope failure, place a blanket or jacket over

Synthetic Rope approximately 5ft - 6ft from Clevis Hook. Open vehicle hood for more

protection.

10. Clear area. Make sure all spectators are away and that no one is directly in front,

behind vehicle, or anchor point.

11. Vehicle to be winched should be placed in neutral and emergency brake released.

Only release brake pedal when Synthetic Rope is under full tension.

12. While standing aside and clear of tow path, use Rocker Switch or Wireless Remote

Control to control winching. If required, wait until Motor stops before reversing

direction.

- Be sure Synthetic Rope is winding evenly and tightly around Winch Drum.

- Vehicle being winched can be slowly driven to add assistance to winching.

- Avoid shock loads; keep Synthetic Rope under tension. This can damage components

and vehicles.

13. Winch is meant for intermittent use. Under full load with a single line rig do not power

“in” for more than (1) minute without letting Motor cool down for a few minutes before

resuming winching.

14. Once vehicle is on stable ground, set brakes and place vehicle in park. Winching

operation is complete.

15. Set Free Spooling Clutch to “CLUTCH OUT” to release tension on Synthetic Rope.

Winch is not meant to hold loads for long periods of time.

16. Disconnect Synthetic Rope from vehicle or anchor.

18. Set Free Spooling Clutch to “CLUTCH IN” position and rewind Synthetic Rope. Keep

hands clear of Winch Drum and components. Any material already on Winch Drum

should be spooled tightly and neatly. Draw out and re-spool if necessary.

19. Secure Hook Strap and Clevis Hook.

- Always leave minimum of (5) turns of Synthetic Rope on Winch

Drum. Review “Safety Warnings” section of manual before continuing.

CAUTION

EWP3500A 12

SYNTHETIC ROPE REPLACEMENT:

If Synthetic Rope has become worn or is beginning to show signs of breaking, replace

immediately.

1. Set Free Spooling Clutch to “CLUTCH OUT” position.

2. Extend installed rope to its full length. Note how it is connected to Winch Drum.

3. Remove and install replacement to Winch Drum in same fashion.

4. Ensure that newly installed Synthetic Rope wraps in same direction as replacement.

Synthetic Rope should leave Winch Drum from bottom.

5. Set Free Spooling Clutch to “CLUTCH IN” position and retract Synthetic Rope onto

Winch Drum for (5) wraps; DO NOT ALLOW KINKING.

- Continue winding onto Winch Drum under a load of at least 10% rated line pull.

WARNING - Only replace with identical part number from manufacturer.

TROUBLE SHOOTING:

Side cutaway view of Winch

Side Cutaway View Of Winch

Rope Exiting

From Under

Drum

SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION

Motor does not

turn on

Rocker Switch not

connected properly. Insert Rocker Switch completely into Controls Splitter.

Loose battery cable

connections. Tighten nuts on all cable connections.

Defective Rocker Switch. Replace.

Defective Motor. Check for voltage at armature port with Rocker Switch

pressed. If voltage is present, replace Motor.

Water has entered Motor. Allow water to drain and Winch to dry. Without a load,

operate Winch in short cycles until completely dry.

Solenoid sticking. Tap on Solenoid with handle end of screwdriver.

Motor runs but

Winch Drum does

not turn.

Free Spooling Clutch not

engaged.

Set Free Spooling Clutch to “CLUTCH IN” position. If

problem persist, contact SuperATV.

Motor runs slowly

or without normal

power.

Insu󰀩cient current or

voltage.

Battery is weak and may need charging. Always

operate Winch with vehicle running.

Corroded and/or loose battery cables should be

cleaned and tightened

Motor overheating. Winch run time too long. Periodically allow Winch to cool while operating.

Motor runs in one

direction only.

Defective Rocker Switch/

Remote Control. Repair or replace Rocker Switch/Remote Control.

Loose battery cable

connections.

Corroded and/or loose battery or Motor cable

connections should be cleaned and tightened.

EWP3500A 13

14.37

6.066.06

4.354.875.154.41

(inches)

MAINTENANCE:

- Check tightness of all mounting hardware and electrical connections periodically.

- Keep Winch clean. Remove all dirt and corrosion as required.

- Do not disassemble Mechanic Gear System. High temperature lithium grease has

been applied at the factory. No user maintenance is required.

SPECIFICATIONS:

Rated Line Pull 3500 lbs (1588 kgs)

Motor: Permanent Magnet 12V: Input: 2.4kW / 3.2hp; Output: 1.0kW / 1.3hp

Gear Reduction Ratio 170:1

Synthetic Rope (Diameter x Length) Ø3/16” x 50’ (Ø4.8mm x 15.2m)

Net Weight 21.8 lbs (9.9 kgs)

Line Pull Line Speed ft/min (m/min) Current

lbs (kgs) 12V DC

010.5 (3.2) 20

1000 (454) 8.9 (2.7) 75

2000 (907) 7.5 (2.3) 130

3500 (1588) 4.6 (1.4) 200

PULL, SPEED, AMPERES, VOLTS (FIRST LAYER):

Control BoxFairlead

Wiring

Wireless

Remote Control

Clevis Hook

and Pin

Mounting Plate

Rocker Switch

Hardware

Ba󰀪e Ring

Solenoid

Controls Splitter Hand Strap

EWX4500A Winch

OPERATING MANUAL

Winch

Read instructions and view illustrations before beginning.

2753 Michigan Road • Madison, Indiana 47250 • 855-743-3427

Thank You

For Choosing

Need help with your installation?

www.superatv.com

8:00am - 9:00pm EST M-Th

8:00am - 7:00pm EST Friday

9:00am - 2:00pm EST Saturday

sales@superatv.com

1-855-743-3427

EWX4500A 2

INTRODUCTION:

Congratulations on your purchase of a high quality winch designed and built to strict

specications. Proper use and maintenance will ensure years of reliable, satisfying

service.

A winch can develop tremendous pulling forces. If winch is used improperly, or in an

unsafe manner, personal injury, death, and/or property damage can occur. Throughout

this operating manual CAUTION, WARNING, and DANGER symbols are present. Pay

particular attention to notes preceded by these symbols as they are written for your safety.

User is responsible for safe operation of this device.

WARNING: Read, study, and follow all instructions before operating winch.

Failure to heed these instructions may result in personal injury, death, and/or

property damage.

Indicates a potentially hazardous situation, which if not avoided,

may result in minor or moderate injury. This symbol is also used

to alert user against unsafe practices.

CAUTION

Indicates a potentially hazardous situation, which if not avoided,

may result in death or serious injury.

WARNING

RECOMMENDED WINCH ACCESSORIES (not included):

Gloves: Protect hands when handling Synthetic Rope.

Anchor Strap/Chain: 5,0000 lbs. - 10,000 lbs. high tensile strength strap.