ramsey winch company owner's manual atv electric winch · ramsey winch company owner's...
TRANSCRIPT
Ramsey Winch CompanyOWNER'S MANUAL
ATV Electric WinchModel ATV3000
* CABLE MUST BE UNIFORMLY WOUND ONTO DRUM.
1,350
3,000
1
2.12
7
ATV3000 WINCH
18
20.8
6.3
LOAD
NO
LAYER OF CABLE
(3/16"-4.8 mm- dia. cable)
3.8
84
680
1,500
6345
4.5
453
1,000
17.6
5.3
227
500
12.315
96
10.2
3.0
906
2,000
11.3
37
857
1,890
4.56
15
1,133
2,500
7.6
25
952
2,100
2 3
15.2
50
761
1,680
4 5
(lbs)
(kgs)
Rated line pull per layer
Cumulative cablecapacity per layer
(ft)*
(m)*
Line pull (lbs)(kgs)
Line speed (fpm)
(mpm)
Amp draw (12v)
2,500
1133
8.5
2.6
121
first layer
first layer
3,000
1360
5.0
1.5
150
CAUTION: Read and understand this manual before installation and operation of winch. SeeSafety Precautions.
CongratulationsYou have purchased the finest winch available in its service class. It features a high-ly efficient 3 stage planetary gear set which transmits torque from a permanent mag-net motor. A safe positive clutch allows free spooling for quick cable deployment.Your Ramsey winch was designed and manufactured to provide you with the utmostin utility. As with any device that combines power and movement in its use, there aredangers if improperly used. At the same time, there are easier and faster ways for get-ting the job done if certain precautions are taken first. Please read this manual care-fully. It contains useful ideas in obtaining the most efficient operation from yourRamsey Winch and safety procedures you need to know before beginning use. Whenyou follow our guidelines for operation, your Ramsey winch will give you many yearsof satisfying service. Thank you for choosing Ramsey. You will be glad you have oneworking for you.Please Note: Ramsey ATV 3000 winches are designed for ATV use. The winches are notdesigned for and should not be used in industrial applications (car haulers /carriers, wreckers,hoisting, etc.), and Ramsey does not warrant them to be suitable for such use. Ramsey makesa separate, complete line of winches for industrial/commercial use. Please contact the factoryfor further information.
Safety Precautions To GuardAgainst Possible Injury.....
A. Keep yourself and others a safe distance tothe side of the cable when pulling under load.
B. Do not step over a cable, or near a cableunder load.
C. Use supplied hook strap when handling hookfor spooling wire rope.
D. Do not use the ATV to pull a load on thewinch cable. This could result in cable break-age and/or winch damage
E. Use a heavy rag or gloves to protect handsfrom burrs when handling winch cable.
F. Apply blocks to wheels when ATV is on anincline.
G. Winch clutch should be disengaged whenwinch is not in use and fully engaged when inuse.
H. Modification, alteration, or deviation to thewinch should only be made by RamseyWinch Company.
I. Keep the duration of your pulls as short aspossible. If the motor becomes uncomfort-ably hot to the touch, stop and let it cool for afew minutes. Do not pull more than oneminute at or near the rated load. Do notmaintain power to the winch if the motorstalls. Electric winches are for intermittentusage and should not be used in constantduty applications.
J. Do not use winch in hoisting applications dueto required hoist safety factors and features.
K. Do not exceed maximum line pull ratingsshown in tables. Shock loads must notexceed these ratings.
L. To respool correctly, it is necessary to keep aslight load on the cable. Do not allow thecable to slip through your hand and do notapproach the winch too closely. When all thecable except a few feet is in, stop and finishspooling in cable by rotating the drum byhand with clutch disengaged. Always usehook strap to hold hook when spooling.
Tips for Safe OperationDon't underestimate the potential danger inwinching operations. Neither should you fearthem. Do learn the basic dangers and avoidthem.
Observe spooling of cable onto drum. Side pullscan cause cable to pileup at one end of the drum.To correct uneven stacking, spool out that sectionof the cable and move it to the other end of thedrum and continue winching. Uneven spoolingwhich causes cable pileup can interfere with thewinch tie rods causing damage to the winch.
Store the wireless remote control transmitter in asafe place where it will not become damaged.Inspect it before you use it.
When ready to begin winching, push and hold theOn/Off button on the transmitter until it flashes.Do not engage clutch with motor running.
Never connect the hook back to the cable. This2
ContentsPerformance Specifications . . . . . . . . . .coverSafety Precautions . . . . . . . . . . . . . . . . . . . .2Tips for Safe Operation . . . . . . . . . . . . . . . .2Techniques of Operation . . . . . . . . . . . . . . .3General Installation . . . . . . . . . . . . . . . . . . .3Rotating the Motor . . . . . . . . . . . . . . . . . .4-7Operating Instructions . . . . . . . . . . . . . . . . .8Maintenance . . . . . . . . . . . . . . . . . . . . . . . .8Cable Installation . . . . . . . . . . . . . . . . . . . . .8Wireless Remote Control Operation . . . . . . .8Trouble Shooting Guide . . . . . . . . . . . . . . . .9Winch Parts List (Wireless Remote) . . .10-11Electrical Schematic (Wireless Remote) . . .11Rocker Switch Operation . . . . . . . . . . . . . .12Rocker Switch Installation . . . . . . . . . .12-14Electrical Schematic (Rocker Switch) . . . .13Winch Parts List (Rocker Switch) . . . . .14-15Warranty . . . . . . . . . . . . . . . . . . .back cover
causes cable damage. Always use a sling orchain of suitable strength.
Observe your winch while winching. If possible,while standing at a safe distance. If you use ATVdrive to assist, stop and get off every few feet toassure the cable is not piling up in one corner.Jamming cable can break your winch.
Do not attach tow hooks to winch mounting appa-ratus. They must attach to ATV frame.
When double lining during stationary winching,the winch hook should be attached to the chassisof the ATV. Since the greatest pulling power isachieved on the innermost layer of your winch, itis desirable to pull off as much line as you can forheavy pulls. If this is not practical, use a snatchblock and double line arrangement.
Neat, tight spooling avoids cable binding which iscaused when a load is applied and the cable ispinched between two other wraps of cable. If thishappens, alternately power the winch in and out afew inches. Do not attempt to work a boundcable under load, free by hand.
Techniques of OperationThe best way to get acquainted with how yourwinch operates is to make a few test runs beforeyou actually need to use it. Plan your test inadvance. Remember you hear your winch as wellas see it operate. Get to recognize the sound of alight steady pull, a heavy pull, and sounds causedby load jerking or shifting. Soon you will gainconfidence in operating your winch and its usewill become second nature with you.
Your winch will not only pull your ATV up or easeyour ATV down a steep grade, it will also pullanother ATV or a load while your ATV is anchoredin a stationary position.
When pulling a heavy load, place a blanket, jacketor tarpaulin over the cable five or six feet from the
hook. It will slow the snap back in the event of abroken cable.
Use the ATV wheel power to help the winch, butdon't overtake the winch line. Plan your pull.You can't always hook up and pull out in one step.Examine all the areas for anchoring possibilitiesas well as leverage situations, direction, and goal.
General InstallationThe winch shown in this owner’s manual is solelyand exclusively designed for ATV mounted, non-industrial applications. All other applications willvoid warranty.
1. Install Winch and Mounting Kit according toinstructions supplied with Mounting Kit.Tighten mounting bolts to 16 ft-lbs torque.
2. It is very important that the winch bemounted on a flat surface, with the cablefeeding from the bottom of the drum.
CAUTION: SUPPLIED 7/8” LONG MOUNTING BOLTS WITH LOCK-WASHERS ARE FOR A RECOMMENDED WINCH MOUNTING PLATE
THICKNESS OF 3/16”. IF A DIFFERENT MOUNTING PLATE THICKNESS
IS USED, THE BOLT LENGTH MUST BE ADJUSTED ACCORDINGLY OR
DAMAGE TO WINCH MAY OCCUR. REPLACEMENT BOLTS MUST BE
SAE GRADE 5 OR EQUIVALENT.
3. Do not attach motor and battery leads untilinstructed to do so.
4. Refer to installation instructions for theWireless Remote Switch (in the ATV Wireless
Installation and Operation Manual) for installa-tion of the switch and electrical assemblies forthe winch.
For basic self-recovery, anchor to a tree or heavy rock.When anchoring to a tree, always use a tree trunk pro-tector.
Winches equipped with cable guide fairleads can pullfrom several directions. Pull from an angle only tostraighten up the ATV-otherwise you can damage struc-tural members or other parts of your ATV and causeexcess cable buildup on one end of the winch drum.
3
Rotating the Motor on your ATVWinchThe ATV winch has the motor studs and leadspositioned on the end of the motor aligned verti-cally. If you need to rotate the motor on your ATVwinch to gain clearance, you can rotate the motor90°. The motor studs will then be aligned horizon-tally.
Before you begin:
Note: If you have installed the optional Brake kit(P/N 256116) for the ATV winch, make sure youhave the Brake kit installation instructions beforeproceeding. You will need to re-install the Brakekit after you rotate the motor (step 6 on the fol-lowing pages). Contact Ramsey if you do nothave your installation instructions.
1. Remove the cable from the drum. Turn theclutch handle to Freespool and pull cable off.Slide the end of the cable out of the pocketnext to the drum flange until the cable anchorcan be removed. Be sure to keep the cableanchor for re-installing the cable. Leave theclutch set to Freespool.
2. Disconnect the motor leads.
3. Remove the winch from its mounting channel.Place it on a sturdy, level workbench.
Set the winch down on the clutch end.
1. Remove the tie bar bolts and nuts. Pull tie barsfrom between end bearings.
2. Lift the motor end off the drum and set downwith the motor end down. Make sure the shaft,drum bushing and spring stay with the drum.
4
3. Remove the bolts that hold the end plate to themotor end housing. Lift off the end plate andtake the nuts and washers out of the mountingfeet. Set aside the gear assemblies and bush-ing. The input sun and planetary gear carriermay come out together.
4. Lean the motor end and loosen the motor tiebolts off the tie bolt nuts. Lean the motor endback up so that it is sitting upright. Do not letthe motor end cap come apart from therest of the motor. Lift the motor end housingand rotate 90°. Put the tie bolt nuts in the otherset of pockets and carefully lean the motor endback. Tighten the tie bolts to 45-50 in-lbs.torque. Do not overtighten.
5. After rotating the motor, the motor end willappear as shown at right. The motor studs willbe aligned horizontally, and the motor tie boltnuts will be in the other set of pockets.
5
6. Replace the gears into the motor end housing,fitting the input sun gear over the motor shaft.The planetary gear carrier should be seated sothat the bushing, as shown at lower right, isflush with the ring gear.
7. Re-install the end plate on the housing withthe bolts you removed earlier. Tighten thesebolts to 45-50 in-lbs. torque. Do not over-tighten.
8. Lift the motor end assembly onto the drum.Turn the drum and motor end assembly sothat the shaft fits into the input sun gear.
Lean the motor end assembly slightly to oneside to insert the tie bars into their holes.
9. Slide the tie bar bolts through the tie bars andinto their nuts. Tighten the tie bar bolts to 45-50 in-lbs. torque. Do not over tighten. The fin-ished winch should look as shown below,with the motor studs aligned horizontally.
Confirm that the drum freespools properly withoutbinding.
Refer to the winch mounting kit installationinstructions for re-installing the winch. Re-installthe winch cable according to the instructions inthis manual.
Insert the mounting nuts and washers into thepockets of the housing as shown. Make sure theydo not fall out while re-installing the end plate.
6
7
NOTES
Operating InstructionsThe winch clutch allows rapid unspooling of the wirerope for hooking onto the load or anchor point. Theclutch is operated by the shifter located on the end ofthe winch as follows:
1. To disengage the clutch, turn the clutch shifter tothe "FREESPOOL" position. Wire rope may now befreespooled off the drum.
2. To engage the clutch, turn the clutch shifter to the"ENGAGED" position. The winch is now ready forpulling.
Your battery must be kept in good condition. A fullycharged battery and proper connections are essential.Run the ATV engine during winching operations to keepbattery charged.
MaintenanceCorrosion on electrical connections will reduce per-formance or may cause a short. Clean all connections.In salty environments use a silicone sealer to protectfrom corrosion.To minimize corrosion of the internal motor componentsthat may occur due to condensation, power the wenchin or out periodically. Energizing the motor will generateheat, which will help dissipate any moisture buildup inthe motor. This should be performed at periodic inter-vals (such as with each oil change of your vehicle).Note: Refer to Troubleshooting Guide if the motor hasbeen submerged.See supplied instructions for programming a replace-ment transmitter.All moving parts in the winch are permanently lubricat-ed with broad temperature range lithium based grease.Lubricate cable periodically using light penetrating oil.Inspect for broken strands and replace if necessary. Ifthe cable becomes worn or damaged, it must bereplaced.
Cable InstallationNote: Cable should be installed so that it feedsfrom the bottom of the drum.
Unwind the new cable by rolling it out along the groundto prevent kinking. Remove old cable and observe themanner in which it is attached to the cable drum flange,watching carefully for the cable anchor puck.
Before installing the new cable assembly, securely wrapthe end of the cable with tape to prevent fraying.
Slide the cable through narrow end of the pocketagainst drum flange and wrap the cable around theanchor puck. Pull the cable and anchor back into thewide end of the pocket leaving approximately 1/8”beyond edge of pocket as shown. Use a hammer anddrift punch to drive the back side of the wire rope, firm-ly seating the wire rope and anchor into the pocket.
Wind on the cable by pulling in a light load to keep thetension constant. Allow the cable to swivel by using alength of chain or a swivel block between the cablehook and the load.
Wireless Remote Control OperationCaution: When the transmitter reaches a tem-perature below 0°F (-18°C) it will not operate.In extremely cold temperatures, keep trans-mitter in a pocket of innermost layer of cloth-ing when not in use.
The transmitter has push buttons labeled according totheir function. Make sure the motor has stopped fullybefore reversing to prevent premature solenoid failure.To operate the winch hold “ON/OFF” button for 2 sec-onds to activate the “IN and “OUT” functions. Runwinch forward and reverse to check connection and toverify winch operating directions. The transmitter isclearly labeled and a red LED flashes when the winch isin operation. Pushing both buttons at the same timewill not damage your winch in any way. Press and holdthe “ON/OFF” button on the transmitter to disable thetransmitter when winch is not in use. This will prolongthe battery life of the transmitter. The transmitter auto-matically turns off after 20minutes.
Refer to page 5 ofRemote ControlInstallation Instructionsfor remote operationnotes.
The short end of the cable shouldextend approximately 1/8” beyond the top edge of pocket.
8
ATV3000 Trouble Shooting Guide
CONDITIONS POSSIBLE CAUSE CORRECTION
MOTOR RUNS IN ONLY ONE Defective solenoid or stuck solenoid. Jar solenoid assembly to free contacts. Check eachDIRECTION solenoid by applying +12 volts to coil terminal (it
should make an audible click when energized).
Defective remote control Check winch operation with auxilliary or low battery in transmitter. toggle switch.
Check battery in transmitter.
Defective Rocker Switch Replace Rocker Switch
MOTOR RUNS EXTREMELY Long period of operation Cooling-off periods are essential to HOT prevent overheating.
MOTOR RUNS, BUT WITH Insufficient battery Test for faulty vehicle battery.INSUFFICIENT POWEROR WITH LOW LINE SPEED Bad connection Check battery cable for corrosion;
clean and grease
Insufficient charging system Replace with larger capacity charging system.
MOTOR RUNS, BUT DRUM Clutch not engaged If clutch engaged but symptoms still DOES NOT TURN exist, it will be necessary to disassem
ble winch to determine cause and repair.
MOTOR WILL NOT OPERATE Defective solenoid or stuck solenoid. Jar solenoid assembly to free contacts. Check solenoid by applying 12 volts to coil terminal (it should make an audible click when energized).
Defective remote control Check winch operation with auxilliary or low battery in transmitter. toggle switch.
Check transmitter battery.
Defective Rocker Switch. Replace Rocker Switch.
Defective motor If solenoids operate, check for voltage at armature post; replace motor.
Loose connections. Check all electrical connections from the battery to the motor.
MOTOR WATER DAMAGED Submerged in water or water Allow to drain and dry thoroughly, then from high pressure car wash Run motor without a load in short
bursts to dry windings.
WINCH RUNS IN OPPOSITE Motor leads crossed. Reverse electrical connections to DIRECTION OF TRANSMITTER motor.BUTTONS
Solenoid control wires Reverse position of green and yellowcrossed. wires on solenoid assembly.
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10
RAMSEY ATV3000 (Wireless Remote)
1
*Hardware Kit
Item No. Qty. Description16-1 4 5/16-18UNC x 1” Hx Hd
Z/P GR5 Capscrew16-2 2 3/8-16UNC x 3/4” Hx Hd
Z/P GR5 Capscrew16-3 2 #10-24UNC x 3/4” Truss
Cross-recess F/B Capscrew16-4 2 3/8-16UNC Hx GR2 Z/P Nut16-5 2 #10-24UNC Hx Locknut16-6 4 5/16 Med Z/P Lockwasher16-7 2 3/8 Med Z/P Lockwasher16-8 2 #10 Flat Washer Z/P16-9 1 Wire Splice16-10 2 Tube Clamp16-11 1 pkg Cable Ties
2 6 3
4 5
7
8
9
12
11
14
10
13
15
16-HardwareKit
9
6 87
1
10
5
4
23
11
11
Winch Parts List ATV3000 (Wireless Remote)
Electrical Schematic (Wireless Remote)
ITEMNO.123456789
10111213141516
QTY.
1111111111111111
PARTNO.
251214251189251191251192251193251194251236251195251196251197282058251190251234251235251198257522
DESCRIPTION
MOTOR KITMOTOR END GEAR SETCLUTCH KITCABLE DRUM KITCABLE & HOOK KITCLUTCH END GEAR KITROLLER FAIRLEAD (ON CERTAIN MODELS)BUSHING KITTIE BAR KITELECTRICAL WIRING KITWIRELESS RECEIVER & TRANSMITTER KITWIRELESS TRANSMITTERSOLENOID KITTOGGLE SWITCHANTENNA KITHARDWARE KIT*
Programing instructions: Press and hold membrane below,
press ON/OFF button on transmitter for 3 seconds ,
press OUT button for 3 seconds or until winch activation .
WWW.RAMSEY.COM
(918)438-2760 FAX(918)438-6688
Tulsa . Oklahoma, USA.
.
PUSH
BLACK WIRETO GROUND
WIRINGHARNESS
YELLOW WIRE
SOLENOID ASS’Y.
BLACK W/YELLOW STRIPEMOTOR LEAD
REDBATTERY LEAD
BLACKBATTERY LEAD
#1
MOTORBATTERY
#2
YELLOW WIRE
YELLOW WIRE
GREEN WIRE
GREEN WIRE
BLACK MOTORLEAD
GREEN WIRE
WIRELESSSIGNAL
RED WIRE W/WHITE STRIPE TO ACCESSORY WIREON VEHICLE IGNI-TION
RED WIRE
ANTENNA
RECEIVERTOGGLE SWITCH
COAX CABLE
FEMALE SPADECONNECTOR
MALE SPADECONNECTOR
NOTE:TORQUE SOLENOIDTERMINAL NUTS TO35-40 IN-LBS.
ON
/OF
F
OU
TIN
TRANSMITTER
WIRE SPLICE
Rocker Switch OperationPress Rocker Switch toward “IN” position to spoolcable “IN” and press Rocker Switch toward “OUT”position to spool cable “OUT”.
12
Rocker Switch InstallationThe Rocker Switch will mount to the handle barsof the ATV.
Before Beginning Installation
1. Install mounting kit and winch according tothe mounting kit instructions.
2. Disconnect negative (-) battery cablefrom battery. Turn off vehicle ignition.
3. Disengage winch clutch.
4. Remove hood or cowling as necessary foreasier access to installation area.
5. Locate and mark mounting location forSolenoid Assembly.
6. Locate accessory wire from vehicle ignitionswitch that is powered only when ignition isON. Use this wire when splicing to Red wireon Rocker switch.
7. Make sure locations are close enough forwiring connections to be made without mak-ing alterations to wire lengths.
CAUTION: DO NOT CONNECT NEGATIVE BATTERY CABLE
OR ENGAGE CLUTCH UNTIL INSTALLATION IS COMPLETE.WINCH COULD BEGIN SPOOLING CABLE UNEXPECTEDLY
CAUSING INJURY OR DAMAGE TO WINCH.
Note: For certain mounting applications, wherethe solenoid needs to be mounted at the rear ofthe vehicle, switch the battery and motor leads.This will allow the longer leads to reach thewinch at the front of the vehicle.
Solenoid Mounting: Choose a mounting locationthat will remain protected and dry. Solenoidshould be mounted on a flat surface.
Installing the Solenoid
1. Use Solenoid Assembly as a guide to markand drill (2) 7/32” holes in location deter-mined for solenoid.
2. Use (2) 3/4” long #10 capscrews (item#14-3), (2) #10 flat washers (item #14-8),and (2) #10 locknuts (item #14-5) to mountsolenoid. Tighten to 60 in-lbs (7 Nm) torque.
Installing the Rocker Switch
For clarification, see wiring schematic on page 9.
1. Position Tube Clamp (item #14-12) on handlebars in convenient location.
2. Mount Rocker Switch housing to Tube Clampusing #10 capscrew, locknut, flat washer,and shake-proof washer (items #14-3, #14-5, #14-8, and #14-9). Tighten securely.
3. Push the Green, Red, and Yellow wiresthrough the back of the switch housing.
Electrical Schematic (Rocker Switch)
13
SOLENOID ASS’Y.
BLACK W/ YELLOWSTRIPE MOTORLEAD
REDBATTERY LEAD
BLACKBATTERY LEAD
BATTERY
YELLOW WIRE
BLACK MOTORLEAD
GREEN WIRE
RED WIREROCKER SWITCH
#1
MOTOR
#2
NOTE:TORQUE SOLENOIDTERMINAL NUTS TO35-40 IN-LBS.
E A
C
B
TO ATV IGNITION
SPLICE
4. Install the Gasket onto the Rocker Switch.
5. Connect Yellow wire (item #12-3) to top ter-minal on Rocker Switch (terminal behind “IN”position). Connect Red wire (item #12-1) tomiddle terminal on Rocker switch. ConnectGreen wire (item #12-2) into bottom terminalof Rocker switch.
6. Slide Green, Yellow, and Red wires into loom(item #12-4). Slide loom up to back of theswitch housing.
7. Snap switch and switch housing together.8. Push Accessory wire from ignition and other
end of Red wire into plastic Splice.
9. Fold splice clip over itself and snap closed.10. Route wires from Rocker Switch down the
handle bars. Turn the handle bars fully rightand left to ensure plenty of clearance.
11. Make sure wires are not drawn taut acrossany surfaces that could damage them. Usecable ties to anchor wires. Tie off excess.
Connect Wiring to Solenoid (unless motor andbattery leads are switched)
CAUTION: TIGHTEN NUTS ON TERMINAL STUDS TO 35-40IN-LBS. (3-4 NM) TORQUE. DO NOT OVER-TIGHTEN.
1. Connect Red Battery Lead (Item #13-2)between “A” terminal on Solenoid and positive(+) vehicle battery terminal.
2. Connect Black Motor Lead (item #13-4)between #2 terminal on motor and C termi-nal on solenoid. Connect Black w/YellowStripe Motor Lead (item #13-1) between #1terminal on motor and B terminal on solenoid.
3. Connect Black Battery Lead (item #13-3) to“E” terminal on Solenoid and route to nega-tive (-) vehicle battery terminal but do notconnect.
IN
OUT
For certain mounting applications, where the solenoid needs tobe mounted at the rear of the vehicle, switch the battery andmotor leads. In this case, connect the black w/yellow stripelead to the positive (+) terminal of the battery, and the longerblack lead to the negative (-) terminal. Connect the red leadand the shorter black lead to the motor terminals.
14
4. Plug Yellow wire from switch into right termi-nal (terminal above black with yellow stripemotor lead). Plug Green wire from switch intoleft terminal (terminal above black motorlead).
Finish Installation
1. Confirm that winch clutch is disengaged.
2. Connect negative (-) battery cable to vehiclebattery. Connect Black Battery Lead fromwinch to negative (-) vehicle battery terminal.
3. With ignition switch OFF, press Rocker switchto “OUT”—winch should not operate. If the
winch does operate with the ignition off, con-firm that proper accessory wire from ignitionwas spliced.
4. Spool a few feet of cable out by hand. Engagewinch clutch. Turn ignition switch ON andpress Rocker switch to “OUT”—winch shouldspool cable out.
6. If winch does not operate with ignition on,check wiring to the schematic on page 14.
7. If winch spools cable IN instead of OUT, turnoff ignition and reverse yellow and greenwires on solenoid.
ATV3000 (Rocker Switch) Parts ListITEMNO.123456789
1011121314
QTY.
11111111111111
PARTNO.
251214251189251191251192251193251213251236251195251196251234257536299728299724257535
DESCRIPTION
MOTOR KITMOTOR END GEAR SET KITCLUTCH KITCABLE DRUM KITCABLE & HOOK KITCLUTCH END GEAR KITROLLER FAIRLEAD KITBUSHING KITTIE BAR KITSOLENOID KITROCKER SWITCH KITSWITCH WIRING KIT1
SOLENOID WIRING KIT2
HARDWARE KIT3
1. Switch Wiring Kit, as shown on facing page,consists of the following components:
ITEM NO. QTY. DESCRIPTION12-1 1 123” RED WIRE12-2 1 123” GREEN WIRE12-3 1 123” YELLOW WIRE12-4 1 24” LOOM
2. Solenoid Wiring Kit, as shown on facingpage, consists of the following components:ITEM NO. QTY. DESCRIPTION
13-1 1 37” MOTOR LEAD - BLACKW/YELLOW STRIPE
13-2 1 97” BATTERY LEAD - RED13-3 1 97” BATTERY LEAD - BLACK13-4 1 37” MOTOR LEAD - BLACK
ATV3000 (Rocker Switch)
15
1 2 6 3
4 5
7
8
9
13
10
14-HardwareKit
96 87
1
10
5
4
23
11
11
3. Hardware Kit consists of the following components:ITEM NO. QTY. DESCRIPTION
14-1 4 5/16-18UNC X 1” LG HX HD Z/P CAPSCREW
14-2 2 3/8-16UNC X 1” LG HX HD GR5 Z/P CAPSCREW
14-3 3 #10-24NC X 3/4 LG TR CROSS RECESS F/B CAPSCREW
14-4 2 3/8-16UNC REG HX HD GR2 Z/P NUT
14-5 3 #10-24NC HEX LOCK NUT14-6 4 5/16” MED Z/P LOCK WASHER14-7 2 3/8” MED Z/P LOCK WASHER14-8 3 #10 Z/P FLAT WASHER14-9 1 #10 SHAKE-PROOF WASHER
14-10 1 WIRE SPLICE14-11 1 PKG CABLE TIES (12 EA)14-12 1 TUBE CLAMP
12
12
RAMSEY WINCH COMPANYP.O. BOX 581510 TULSA, OKLAHOMA 74158-1510 USA PHONE: (918) 438-2760 FAX: (918) 438-6888
http://www.ramsey.comOM-914053-0105-R
Warranty InformationRamsey Winches are designed and built to exacting specifications. Care and skill go into every winch we make.If the need should arise, warranty procedure is outlined on the back of your self-addressed, postage paid war-ranty card. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company. If youhave any problems with your winch, please follow instructions for prompt service on all warranty claims.
Limited Lifetime WarrantyRamsey Winch offers a limited lifetime warranty for each new Ramsey ATV winch against manufacturing defects in workmanship and materials on allmanufactured components.
Warranty registration cards for each winch must be submitted at the time of purchase, or within 90 days. Online registration of your winch is availableat www.ramsey.com.
New cable assemblies are warranted against defects in workmanship and materials. No warranty applies after initial use.
All Ramsey mounting kits and other accessories carry a 1- year limited warranty against defects in materials and workmanship.
This warranty is void if winch is used in industrial applications.
Electrical components consisting of motors, solenoids, wiring, wire connectors, and associated parts carry a limited 1-year warranty.
The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at the manufacturers factory, or at a point designated bythe manufacturer, of such part as shall appear to the manufacturer, upon inspection of such part, to have been defective in material or workmanship. ThisWarranty does not obligate Ramsey Winch Company to bear the cost of transportation charges in connection with the replacement or repair of defectiveparts, nor shall it apply to a product upon which repairs or alterations have been made, unless authorized by the manufacturer, or for equipment misused,neglected, or improperly installed.
Important notice: To the fullest extent permitted by applicable law, the following are hereby excluded and disclaimed: 1. All warranties offitness for a particular purpose; 2. All warranties of merchantability; 3. All claims for consequential or incidental damages. There are nowarranties that extend beyond the description that appears on the face hereof.
Some states do not allow the above exclusions or disclaimers in consumer transactions and as such this disclaimer/exclusion may not applyto your particular case.
To the extent such warranties of fitness for a particular purpose or merchantability are deemed to apply to this product, they exist only forso long as the express limited warranty elsewhere set forth is in existence.
Ramsey Winch Company makes no warranty in respect to accessories, same being subject to the warranties of their respective manufacturers.
Ramsey Winch Company, whose policy is one of continuous product improvement, reserves the right to improve any product through changes in designor materials as it may deem desirablewithout being obligated to incorporate such changes in products of previous manufacture.
If field service at the request of the buyer is rendered and the fault is found not to be with Ramsey Winch Company’s product, the buyer shall pay thetime and expense of the field representative. Bills for service, labor or other expenses which have been incurred by the buyer without express approval orauthorization by Ramsey Winch Company will not be accepted.
This Warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.
INSTALLATION AND OPERATINGINSTRUCTIONS FOR RAMSEY
WIRELESS REMOTE CONTROLFOR THE ATV WINCH
Warnings
1. THE RAMSEY WIRELESS REMOTE FOR THE ATV WINCH IS DESIGNED
FOR USE ON SELF-RECOVERY WINCHES ONLY. THE REMOTE IS NOT
DESIGNED FOR AND SHOULD NOT BE USED ON WINCHES OR HOISTS IN
INDUSTRIAL APPLICATIONS (CAR HAULERS/CARRIERS, WRECKERS,CRANES, ETC.) OR FOR ANY OTHER REMOTE CONTROLLED APPLICATION.
2. WHEN REELING IN CABLE UNDER NO LOAD, RELEASE THE REMOTE BUT-TON WHEN THE HOOK IS A MINIMUM OF 3 FT (1 M) FROM THE WINCH
FAIRLEAD. CAREFULLY JOG THE REMOTE CONTROL BUTTON UNTIL THE
HOOK IS A MINIMUM OF 1 FT (.3M) FROM THE FAIRLEAD. DISENGAGE
THE CLUTCH AND FINISH SPOOLING IN CABLE BY ROTATING THE DRUM BY
HAND.
3. When finished winching, turn transmitter off.
4. Do not pressure wash or steam clean the receiver. This candamage the receiver and adversely affect operation.
5. Refer to winch owner’s manual for all winch operating instruc-tions and warnings.
The following are general installation instructions. Actualinstallation may vary depending on the ATV manufacturerand model.
NOTES
Contents
Parts List .........................................................1Before Beginning Installation ............................2Installation .......................................................2-4Electrical Schematic ........................................5Testing & Operation .........................................6Troubleshooting Guide......................................7
* SONY CR2032 OR DURACELL DL2032
ITEMNO.12345678910111213
QTY.
1111122211211
PARTNO.
282058251198251234251190
*416227
418140440125251235
440274251197
DESCRIPTION
WIRELESS RECEIVER & TRANSMITTER KITDIPOLE ANTENNA KITSOLENOID KITREPLACEMENT TRANSMITTERREPLACEMENT BATTERYSCREW #10-24 X 3/4 TRUSS F/BNUT #10-24 HEX LOCKFLAT WASHER #10 Z/PWIRE SPLICETOGGLE SWITCHTUBE CLAMPCABLE TIESWIRE KIT
1
REMOTE RECEIVER
CABLE TIE
ANTENNAMOUNTINGSCREWS
REMOTETRANSMITTER
SOLENOID
TOGGLE SWITCH
TUBE CLAMP
WIRE SPLICE
FLATWASHERS
LOCK NUTS
WIRE KIT
Before Beginning Installation
1. Disconnect power lead from winch to battery. 2. Disengage winch clutch.3. Remove hood or cowling as necessary for easier access to installation
area.4. Locate & mark mounting locations for receiver, toggle switch, solenoid
assembly, & antenna. NOTE: Make sure locations are close enough for wiring connections tobe made without making alterations to wire lengths. Solenoid assemblywill be mounted to tube frame of ATV using supplied tube clamps,except Polaris models which mount directly to the ATV cross memberunder hood using supplied mounting screws. For certain mounting applications, where the solenoid needs to bemounted at the rear of the vehicle, switch the battery and motor leads.This will allow the longer leads to reach the winch at the front of thevehicle.The antenna will need a space of at least 15” wide under cowling orhood for mounting in the horizontal configuration required for bestreception. Antenna is flexible and will follow the contour of the cowlingor hood. The antenna should be mounted at least 10” from winch motorand battery leads.
Installing the Receiver
1. Insert plastic tie through mounting ears on receiver and secure receiver tolocation determined above.
2. Tighten plastic tie and clip excess.
3. Attach ground wire to ATV frame.
CAUTION: DO NOT ALTER THE LENGTH OF THE GROUND WIRE ASTHIS WILL AFFECT PERFORMANCE OF THE REMOTE.
4. Attach wiring harness to receiver & route yellow and green wires to sole-noid location.
Installing the Motor Leads (unless motor and battery leads are switched)
1. Connect black wire to #2 stud on motor.
2. Connect black with yellow stripe wire to #1 stud.
3. Route wires to solenoid location.
2
NOTE: For clarification see wiring schematic on page 5.1. Attach black with yellow stripe motor lead to lower right terminal stud
“B” on solenoid.2. Attach black motor lead to lower left terminal stud “C” on solenoid .3. Attach connector with 2 yellow wires to the terminal directly above the
black with yellow stripe motor lead. 4. Attach connector with 2 green wires to the terminal directly above the
black motor lead.5. Attach black battery lead to upper left terminal stud “E” on solenoid.6. Attach red battery lead to upper right terminal stud “A” on solenoid.
Connecting Wiring to Solenoid (unless motor and battery leads areswitched)
Installing the Solenoid
1. Mount solenoid in location determined previously.
2. Secure using (1) tube clamp, (1) #10-24 screw, (1) flat washer,and (1) lock nut each side of solenoid assembly.
CAUTION: BE SURE THAT NO WIRE CONNECTIONS ARE INCONTACT WITH EITHER THE ATV FRAME OR WITH EACHOTHER AS A DIRECT SHORT WILL OCCUR.
Installing the Toggle Switch
1. Route red, yellow and green wires to toggle switch location.
2. Drill 1/2” hole in location for toggle switch installation.
3. Insert switch through hole drilled in previous step.
4. Place directional plate over switch and secure using knurled nut.Using wrench, tighten backup nut securely against inside of instru-ment cover. Make sure directional plate is installed in the samedirection as the toggle switch movement.
5. Place rubber boot over switch and tighten securely.
3
NOTE: For clarification see wiring schematic on page 5.
1. Connect red wire to center spade. 2. Connect green wire to the toggle switch terminal in the “OUT”
position.3. Connect the yellow wire to the toggle switch terminal in the “IN”
position.
1. Locate accessory wire from ATV ignition.
NOTE: ATV accessory wire should have 12 volts only whenignition key is on. Receiver should only have power when vehi-cle ignition is ON.
2. Connect red wire with white stripe to accessory wire. Use sup-plied quick splice connector if needed.
Wiring the Toggle Switch
Connecting the Power Lead
Installing the Antenna
NOTE: For clarification see wiring schematic on page 5.
1. Clean predetermined mounting surface with Isopropyl alcohol andbuff dry. (In ATVs without hoods the best place to mount theantenna will be the underside of the ATV cowling in the highestpossible position.)
2. Remove backing from top side of double-stick tape and apply toback side of pc board. Remove backing from other side of dou-ble-stick tape and position pc board in center on top inside sur-face of cowling or hood at the predetermined mounting location.
3. Remove backing from copper tape. Carefully affix tape to terminalon right side of pc board and follow contour of inside of cowling.DO NOT ALTER LENGTH OF THE TAPE. Repeat for left side.
4. Route coax cable up from receiver to antenna and plug in at pcboard.
4
5
Programing instructions: Press and hold membrane below,
press ON/OFF button on transmitter for 3 seconds ,
press OUT button for 3 seconds or until winch activation .
WWW.RAMSEY.COM
(918)438-2760 FAX(918)438-6688
Tulsa . Oklahoma, USA.
.
PUSH
BLACK WIRETO GROUND
YELLOW WIRE
SOLENOID ASS’Y.
BLACK W/ YELLOWSTRIPE MOTORLEAD
REDBATTERY LEAD
BLACKBATTERY LEAD
BATTERY
YELLOW WIRE
YELLOW WIRE
GREEN WIRE
GREEN WIRE
BLACK MOTORLEAD
GREEN WIRE
WIRELESSSIGNAL
RED WIRE W/WHITE STRIPE TOACCESSORY WIREON VEHICLE IGNI-TION
RED WIRE
ANTENNA
RECEIVER
TOGGLE SWITCH
COAX CABLE
OUT
IN
Electrical Schematic
WIRING HARNESS
#1
MOTOR
#2
NOTE:TORQUE SOLENOIDTERMINAL NUTS TO35-40 IN-LBS.
MALE SPADECONNECTOR
FEMALE SPADECONNECTOR
E A
C
B
TRANSMITTER
For certain mounting applications, where the solenoid needs tobe mounted at the rear of the vehicle, switch the battery andmotor leads. In this case, connect the black w/yellow stripelead to the positive (+) terminal of the battery, and the longerblack lead to the negative (-) terminal. Connect the red leadand the shorter black lead to the motor terminals.
WIRESPLICE
6
1. Reconnect the positive power lead fromsolenoid to battery.
2. Pull approximately 20 ft of cable off thewinch by hand.
3. Re-engage the winch clutch.
4. Test the remote transmitter. The trans-mitter has push buttons labeled accord-ing to their function. To operate thewinch, hold “ON/OFF” button for 2 seconds to activate the “IN” and “OUT”functions. (1 flash indicates transmitter is “ON”, 2 flashes indicate transmit-ter is “OFF”).
6. Run winch in the “OUT” direction briefly. Make sure the motor has stoppedfully before reversing to prevent premature solenoid failure. Run winch in the“IN” direction briefly.
7. Follow instructions in your winch owner’s manual for properly reeling in therest of the cable. The transmitter is clearly labeled and a red LED flasheswhen the winch is in operation. To turn transmitter off, press and hold the“ON/OFF” button for 2 seconds to disable the transmitter when winch is notin use. This will prolong the battery life of the transmitter. The transmitterautomatically turns off after 20 minutes.
PROGRAMMING THE RECEIVER FOR USE WITH A REPLACEMENT TRANSMITTER
When you purchase a replacement transmitter, it will be necessary to programyour receiver to accept the code for the new transmitter. To program the receiver,press and hold membrane located in the center of receiver face (area marked“push”). Press and hold “ON/OFF” button on transmitter for 3 seconds. Pressand hold “OUT” button for 3 seconds or until winch activates.
CAUTION: The center membrane area of the receiver face must only be pressedwhen programming a new transmitter.
Testing/Operation
OUTIN
ON/OFF
LED
Transmitter
Trouble Shooting GuideCorrectionTurn transmitter on (SeeTesting/Operation) .
Replace Battery.
In extremely cold tempera-tures, keep transmitter in apocket of innermost layerof clothing when not inuse.
Make sure receiver groundwire has good connectionto ATV ground.
Program receiver (refer toProgramming theReceiver).
Mount antenna at least 10inches from winch motorand battery leads.
Move the transmitteraround the ATV until nor-mal operation resumes .
Keep transmitter in directline of sight with antennafor optimal operation.
Stay within 50 ft. of anten-na for optimal operation.
Make sure no similardevices are within 50 ft. ofvehicle.
Make sure ATV batteryvoltage is above 9.5 volts.
Possible CauseTransmitter is off.
Low transmitter batteryvoltage.
Transmitter temperaturebelow 0°F (-18°C).
Bad ground connection.
Receiver not coded withtransmitter.
Antenna mounted tooclose to winch motor andbattery leads.
External environmentalconditions causing inter-mittent operation in aspecific transmitter loca-tion.
Signal deflecting off ofland mass or solid structures.
Transmitter out of oper-ating range.
Operating within 50 ft. ofany similar device.
Low ATV battery voltage.
ConditionTransmitter won’t operate
Remote receiver will notoperate.
Intermittent operation.
7
NOTES
RAMSEY WINCH COMPANYP.O. BOX 581510 TULSA, OKLAHOMA 74158-1510 USA PHONE: (918) 438-2760 FAX: (918) 438-6888
http://www.ramsey.com
OM-914062-0106-H
Warranty InformationIf the need should arise, warranty procedure is outlined on the back of your self-addressed, postage paid warrantycard. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company. If you have anyproblems with your wireless remote, please follow instructions for prompt service on all warranty claims.
Limited Lifetime WarrantyRamsey Winch offers a limited lifetime warranty for each new Ramsey wireless remote against manufacturing defects in workmanshipand materials on all manufactured components.
The wireless remote carries a limited 1-year warranty.
The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at the manufacturers factory, or at apoint designated by the manufacturer, of such part as shall appear to the manufacturer, upon inspection of such part, to have beendefective in material or workmanship. This Warranty does not obligate Ramsey Winch Company to bear the cost of transportationcharges in connection with the replacement or repair of defective parts, nor shall it apply to a product upon which repairs or alterationshave been made, unless authorized by the manufacturer, or for equipment misused, neglected, or improperly installed.
Important notice: To the fullest extent permitted by applicable law, the following are hereby excluded and disclaimed: 1.All warranties of fitness for a particular purpose; 2. All warranties of merchantability; 3. All claims for consequential orincidental damages. There are no warranties that extend beyond the description that appears on the face hereof.
Some states do not allow the above exclusions or disclaimers in consumer transactions and as such this disclaimer/exclu-sion may not apply to your particular case.
To the extent such warranties of fitness for a particular purpose or merchantability are deemed to apply to this product,they exist only for so long as the express limited warranty elsewhere set forth is in existence.
Ramsey Winch Company makes no warranty in respect to accessories, same being subject to the warranties of their respective man-ufacturers.
Ramsey Winch Company, whose policy is one of continuous product improvement, reserves the right to improve any product throughchanges in design or materials as it may deem desirable without being obligated to incorporate such changes in products of previousmanufacture.
If field service at the request of the buyer is rendered and the fault is found not to be with Ramsey Winch Company’s product, the buyershall pay the time and expense of the field representative. Bills for service, labor or other expenses which have been incurred by thebuyer without express approval or authorization by Ramsey Winch Company will not be accepted.
This Warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.