SuperATV EWX4500A User manual

EWX4500A Winch
OPERATING MANUAL
Read instructions and view illustrations before beginning.
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Winch
Control Box
Fairlead
Wiring
Wireless
Remote Control
Clevis Hook
and Pin
Mounting Plate
Rocker Switch
Hardware
Bafe Ring
Solenoid
Controls Splitter Hand Strap
© 2015 SuperATV.com®All Rights Reserved. Rev EWX4500A 10/19/2015
Thank You
For Choosing
740B Clifty Drive • Madison, Indiana 47250 • 812-574-7777
Liability Statement
SuperATV’s® products are designed to best t 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 satised 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 modied.

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

EWX4500A 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: 3.2/3.9hp motor powered by a 12/24 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: Ø1/4” x 47.6’ long Synthetic Rope designed specically for a load
capacity of 4500lbs. 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.

EWX4500A 4
- Remove all jewelry and wear eye protection when making battery
connections. Batteries contain ammable and explosive gases.
Avoid leaning over battery.
CAUTION
4x
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:
Winch is designed with a standard bolt pattern for its class. Different 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 Baf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.

EWX4500A 5
Bafe Ring
Hand Strap
install onto Synthetic Rope
and replace Lock
WINCH ASSEMBLY AND MOUNTING (continued):
Pin
remove Lock
(tap with a hammer)

EWX4500A 6
Winch
Control Box
Rocker Switch
Solenoid
Controls Splitter
Connect
Connect Connect
Connect to Battery
Connect to Solenoid
Connect to Solenoid
Connect to Winch
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, “+”

EWX4500A 7
WARNING - Do not exceed rated capacity shown in following table.
Layer Rated Line Pull lbs (kgs) Total Rope On Drum ft (m)
14500 (2041) 7.6 (2.3)
23642 (1652) 17.0 (5.2)
33060 (1388) 27.0 (8.3)
42638 (1196) 38.6 (11.8)
52254 (1023) 47.6 (14.5)
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.

EWX4500A 8
(Safety Precautions continue on following page)
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 off 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
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

EWX4500A 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 off.
• 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.

EWX4500A 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.