Polaris PRO HD 4500 Manual 

NOTE You must order below mentioned power cables kit separately to connect battery to the vehicle bus bar. • For 3 Seat Models : PN 2881684 • For Crew Models : PN 2881685 BEFORE YOU BEGIN Read these instructions and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information. KIT CONTENTS This Kit includes: ...

Page 2 of 13 REF QTY PART DESCRIPTION PART NUMBER 5 1 Wireless Remote Kit 2879316 6 1 Winch Cable, Yellow 6 GA 4013468-740 7 1 Winch Cable, Blue 6 GA 4013469-740 8 1 Power Cable, Black 4013470-480 9 1 Power Cable, Red 4013471-480 10 1 Contactor 4015095 11 1 Autostop Fairlead ** 12 1 Grill, Fairlead Cover 5255409 13 1 Winch Mount Bracket - 14 1 Rubber Stop Magnet ** 15 10 Panduit Strap 7080492 16* 4 Screw Hex Head - M8 X 1.25 X ...

Page 3 of 13 Power Cable Kit (PN 2881684) Includes: REF QTY PART DESCRIPTION PART NUMBER 28 1 Power Cables, Vehicle Bus Bar to Battery 4015881 1 Instructions 9926841 TOOLS REQUIRED • Safety Glasses • Socket Set, SAE • Socket Set, Metric • Wrench Set, SAE • Wrench Set, Metric • Phillips Screwdriver • Socket Set, Torx® Bit • Pliers, Side Cutting IMPORTANT Your POLARIS® PRO HD 4500 WINCH KIT is exclusively design ...

Page 4 of 13 INSTALLATION INSTRUCTIONS PREPARATION 1. Shift vehicle transmission into “PARK”. Turn key to “OFF” position and remove from vehicle. 2. Remove the driver seat and disconnect black negative cable first and then red positive cable from the battery. 3. Remove the front bumper A by removing seven bolts B. 4. Remove grill screen C from bumper by removing two screws D. Retain screws for reuse. 5. Detach rubber la ...

Page 5 of 13 CONTACTOR INSTALLATION 1. Install contactor a to center frame member under hood using two screws 1( as shown. Tighten just until snug. Do not overtighten. 2. Connect short (250mm) red i and black o cables to the vehicle bus bar as shown. Connect the other ends of cables to their respective colored posts on contactor and torque to specification. Slide the cable covers on as shown. TORQUE 4ft. lbs. (5.4 Nm) WINCH INS ...

Page 6 of 13 4. Install winch q onto the winch mounting bracket using four screws j, split washers 2$, and flat washers 2% as shown and torque to specification. TORQUE 20ft. lbs. (27.1 Nm) 5. Insert winch rope r through autostop fairlead s and rubber stopper g as shown. Install hook w onto the rope using clevis and cotter pins. HINT: Attach a plastic cable tie to the end of the rope and feed the cable tie through the rubber sto ...

Page 7 of 13 TORQUE 4ft. lbs. (5.4 Nm) CONTROL BOX INSTALLATION 1. Position control as shown behind the radiator and fasten to chassis with supplied cable ties as shown. Connect white electrical connectors for the control box as seen in the top photo of the Electrical Connections Reference Guide section of your instructions. 2. Route power wires from control box to bus bar and connect red positive (+) (or orange depending on th ...

Page 8 of 13 FINAL INSPECTION 1. Confirm that all wiring is correct. 2. Confirm that there are no exposed wires or terminals. 3. All loose wires need to be secured away from moving parts and heat sources. REINSTALLATION 1. Re-connect the main vehicle battery cables and cables from power cable kit 2* to battery terminals using original hardware. 2. Reinstall drive shaft cover H using retained screws G. 3. Reinstall the hood E on ...

Page 9 of 13 GEAR SELECTION WARNING Attempting to shift the winch while the rope is under tension is dangerous and can result in injuries or death. Make sure the winch rope is not in tension before shifting the winch between gears. Your winch is equipped with three different gear settings. High, Neutral and Low. When in neutral the “N” marking will show thru the cutout window on the shift knob. See photo below. The high gea ...

Page 10 of 13 RAPID RECOVERY WINCH FUNCTION NOTE Rapid Recovery is for recovering the winch rope only. It is not intended for pulling and will reduce the life of the winch if used under load. Your winch is equipped to quickly reel in the winch rope when being used under no-load conditions. Using this feature will significantly reduce the time it takes to rewind your rope after use. When to use Use Rapid Recovery to quickly reel ...

Page 11 of 13 TROUBLESHOOTING If your winch/Autostop is not functioning properly, below is a short guide that can help you diagnose and correct the problem. SYMPTOM POSSIBLE CAUSES RECOMMENDED SOLUTION Dead Vehicle Battery Check that all power wires are connected to the correct terminals per your instruction manual and not drawing any current while the vehicle sits for longer periods of time. Rewire to ensure wiring is connecte ...

Page 12 of 13 SYMPTOM POSSIBLE CAUSES RECOMMENDED SOLUTION Winch makes noise but rope does not move Winch not in proper gear Rotate gear knob fully into L or H, then recheck. Winch operates too slowly Winch in wrong gear Rotate gear knob into proper gear, then recheck. Winch improperly loaded The winch, by design, operates slowly in Low gear. In High (Rapid Recovery), the winch operates quickly but can be slowed if there is a l ...

Page 13 of 13 ELECTRICAL CONNECTION REFERENCE GUIDE Winch with auto fairlead and wireless remote FEEDBACK FORM A feedback form has been created for the installer to provide any comments, questions or concerns about the installation instructions. The form is viewable on mobile devices by scanning the QR code or by clicking HERE if viewing on a PC. FEEDBACK FORM ...