SuperATV WN-3500 User manual

WN-3500 / WN-4500 / WN-5000 Winch guide
Stopper
Rocker Mount
Mounting Plate
Clevis Pin and Hook
Wireless Remote
Winch
Rocker Switch
Wiring Accessory Kit
Hand Strap
© 2018 SuperATV.com®. All Rights Reserved. WN-Winch-Guide 11/2/2018
Fairlead
(kit contents continue on following page)
Solenoid

WN-3500 / WN-4500 / WN-5000 2
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.
Hardware Kit
Stopper Hardware
Blue Wire
(6’ long)
Yellow Wire
(kit contents continued)
Black Wire
Red Wire
(12’ long)

WN-3500 / WN-4500 / WN-5000 3
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
WIRING:
Winch NEG “-” Winch POS “+”
Winch
User may shorten wire length with components included in Wiring Accessory Kit.
to Battery, NEG “-”
to Battery, POS “+”
to Winch, POS “+”
to Rocker Switch
Solenoid
to Winch, NEG “-”
Solenoid

WN-3500 / WN-4500 / WN-5000 4
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 Mechanical 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: Designed specically for Winches load capacity 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.
Mechanical 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 Mechanical Gear System; free spool. Engaging clutch (“CLUTCH IN”) locks Winch
into Mechanical 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.

WN-3500 / WN-4500 / WN-5000 5
WARNING - Do not exceed rated capacity. See “Performance Data”, page 6.
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:
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.
(Safety Precautions continue on following page)
WARNING - Apply blocks to wheels of vehicle when on an incline.

WN-3500 / WN-4500 / WN-5000 6
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
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

WN-3500 / WN-4500 / WN-5000 7
Line Pull
(lbs - kgs)
Line Speed
(Ft/min, M/min)
Motor
(amps)
Pull by Layer
(layer/lbs - kgs)
0 9.5 (2.9) 11 1/3500 (1590)
500 (454) 9.2 (2.8) 30 2/2640 (1198)
1000 (907) 8.5 (2.6) 40 3/2320 (1052)
1500 (680) 7.9 (2.4) 60 4/2040 (925)
2000 (907) 7.2 (2.2) 70
2500 (1134) 6.6 (2.0) 80
3000 (1361) 5.2 (1.6) 95
3500 (1588) 4.6 (1.4) 180
Model WN-3500
Line Pull
(lbs - kgs)
Line Speed
(Ft/min, M/min)
Motor
(amps)
Pull by Layer
(layer/lbs - kgs)
0 18.63 (5.68) 24 1/4500 (2045)
1000 (454) 14.13 (4.31) 86 2/3600 (1636)
2000 (907) 12.33 (3.76) 155 3/3130 (1423)
3000 (1361) 7.25 (2.21) 229 4/2745 (1248)
4000 (1814) 4.1 (1.25) 256
4500 (2041) 2.98 (.91) 278
Model WN-4500
Line Pull
(lbs - kgs)
Line Speed
(Ft/min, M/min)
Motor
(amps)
Pull by Layer
(layer/lbs - kgs)
0 20.5 (6.2) 30 1/5000 (2268)
1000 (454) 16.1 (4.9) 83 2/4080 (1851)
2000 (907) 12.8 (3.9) 136 3/3450 (1565)
3000 (1361) 10.7 (3.3) 168 4/2985 (1354)
4000 (1814) 8.6 (2.6) 232
5000 (2268) 6.1 (1.9) 296
Model WN-5000
PERFORMANCE DATA:
12V DC Motor, 1.2hp output
12V DC Motor, 1.3hp output
12V DC Motor, 1.5hp output

WN-3500 / WN-4500 / WN-5000 8
Pulley/Snatch Block Winch
Anchor point
on vehicle
Synthetic Rope
to sling/tree stap
and anchor point
GENERAL TIPS FOR SAFE OPERATION:
• Winch is at rated 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.
- 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

WN-3500 / WN-4500 / WN-5000 9
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.
When installing, ensure that Mounting Plate installs 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 supplied hardware.
2. Install Winch to Mounting Plate with supplied hardware:
- Set Free Spooling Clutch to “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; See SuperATV instructions.
4. Assemble Clevis Hook to Synthetic Rope.
- Remove Pin from Clevis Hook and connect Clevis Hook to Synthetic Rope.
- Reinstall Pin to Clevis Hook.
5. Install Stopper to Synthetic Rope.
6. Install Hand Strap to Clevis Hook.
7. Check Winch Drum for proper rotation:
- Set Free Spooling Clutch to “OUT” and pull out some Synthetic Rope.
- Set Free Spooling Clutch to “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
Universal Mounting Plate is supplied. Machine specic
Mounting Plates are available at www.SuperATV.com
Clevis Hook
Pin
Stopper half
Synthetic Rope
Stopper half
M6 x 35mm
M6 Washer
M6 Nut
(4) each
Hand Strap

WN-3500 / WN-4500 / WN-5000 10
Rocker
Rocker Mount
Rocker Mount
Rocker
Handlebar
Handlebar
ROCKER MOUNTING:
Rocker can be mounted to Handlebar as shown below.
Rocker Switch
Red Wire must be connected to a
switched 12V source (Ignition Key)

WN-3500 / WN-4500 / WN-5000 11
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.

WN-3500 / WN-4500 / WN-5000 12
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 “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 “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 “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

WN-3500 / WN-4500 / WN-5000 13
SYNTHETIC ROPE REPLACEMENT:
If Synthetic Rope has become worn or is beginning to show signs of breaking, replace
immediately.
WARNING - Only replace with identical part number from manufacturer.
TROUBLE SHOOTING:
SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION
Motor does not
turn on
Rocker Switch not connected
properly.
Insert Rocker Switch completely into Controls
Splitter Connector.
Connect ignition power source.
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 “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.
Motor runs
continuously on its
own.
Defective Solenoid, Wireless
Receiver, or Remote Control.
Unplug ignition power.
Remove negative battery cable from Solenoid.
When installing replacement, refer to SuperATV instructions.
MAINTENANCE:
- Check tightness of all mounting hardware and electrical connections periodically.
- Keep Winch clean. Remove all dirt and corrosion as required.
- Do not disassemble Mechanical Gear System. High temperature lithium grease has
been applied at the factory. No user maintenance is required.

WN-3500 / WN-4500 / WN-5000 14
(all dimensions shown are in inches)
13
4.72
4.884.49
4.6
3
Model WN-3500
14.76
4.72
6.614.52
4.6
3
Model WN-4500
15.55
4.72
6.615.31
4.6
3
Model WN-5000
WN-3500: Synthetic Rope (Diameter x Length): Ø7/32” x 50’ (Ø5.5mm x 15.2m)
WN-4500
WN-5000
:Synthetic Rope (Diameter x Length): Ø1/4” x 50’ (Ø6.3mm x 15.2m)