® Extreme Heavy Duty ATV/UTV Recovery Winch 2.0 - 2.
ATV/UTV RECOVERY ELECTRIC WINCH USE & INSTALLATION INSTRUCTIONS ® A FEW WORDS ABOUT PRODUCT SAFETY Your Rugged Ridge® ATV/UTV recovery winch is a powerful tool adding considerable utility and enjoyment to your off road ATV/UTV.
Table of Contents: Winch Packing List .......................................................03 Safety Warnings & Precautions ....................................04 Winch Assembly & Mounting (2.0 Model) ....................09 Winch Assembly & Mounting (2.5 Model).....................10 • Mount Winch ......................................................10 • Mount Control Box ............................................11 • Mount Connector for Remote ...........................12 • Install Wiring ..........
Installing Your Winch Take a moment to read and understand all instructions and safety information before attempting installation or use of your Rugged Ridge® ATV/UTV recovery winch. Specifications and sample performance (line speed & pull) for your model winch are set out on pages 20-21 herein. If you have any questions regarding the installation and operation of your ATV/UTV winch, contact Rugged Ridge® Technical Support at 770-614-6101.
Moving Parts Entanglement Hazard Failure to observe these instructions could lead to minor or moderate injury. • Always keep wired remote control lead clear of the drum, rope and rigging. Inspect for cracks, pinches, frayed wires or loose connections. Replace remote control if damaged. • Never leave remote control where it can be activated during freespooling, rigging, or when the winch is not being used • Always require operator and bystanders to be aware of ATV/ UTV and or load.
• Always mount the winch and attach the hook to the rope`s end loop before connecting the electrical wiring. • Always spool the rope onto the drum in the direction specified by the winch warning label on the winch and/or documentation. This is required for the automatic brake (if so equipped) to function properly. • Always prestretch wire rope and respool under load before use. Tightly wound wire rope reduces chances of binding , which can damage the rope.
Moving Parts Entanglement Hazard Failure to observe these instructions could lead to minor to moderate injury. • Always use a hook with a latch • Always insure hook latch is closed and not supporting load. • Never apply load to hook tip or latch. Apply load only to the center of hook. • Never use a hook whose throat opening has increased, or whose tip is bent or twisted. Falling or Crushing Hazard Failure to observe these instructions could lead to severe injury or death.
Avoid Winch and Equipment Damage • Always avoid side pulls which can pile up rope at one end of the drum. This can damage rope or winch. • Always ensure the clutch is fully engaged or disengaged. • Never use winch to tow other vehicles or objects. Shock loads • • • • • • • can momentarily exceed capacity of rope and winch. Always avoid “powering out” for extended distances. This causes excess heat and wear on the winch motor and brake.
Winch Assembly and Mounting for 2.0 Model Step 1 - Mount the Winch Consult your ATV/UTV manufacturers owner’s manual for all specific winch related recommendations, instructions and warnings before installation. To secure the winch, always use: • A flat, secure mounting location at least 4.8 mm (3/16 in.) Thick. • Lock washers. • Hex head cap screws when using a one-piece winch mount plate.
Winch Assembly and Mounting for 2.5 Model Figure 1: To install the complete kit, you will need to mount the winch, control box, handlebar mounted Mini-rocker switch and remote socket. Step 1 - Mount the Winch Consult your ATV/UTV manufacturers owner’s manual for all specific winch related recommendations, instructions and warnings before installation. To secure the winch, always use: • A flat, secure mounting location at least 4.8 mm (3/16 in.) Thick. • Lock washers.
Figure 2: Orientation of winch to mounting plate and bolt lengths Step 2 - Mount the Control Box The control box is a primary safety feature in your winch system. It disconnects your winch from its power source when the ATV is not in use.The control box must be correctly installed to work properly. It is recommended that the control box be mounted close to the battery and in a location that is as clean and dry as possible. Exact location will vary, depending on the ATV.
Step 3 - Mount the Connector for Remote TO PREVENT SERIOUS INJURY OR DEATH FROM EXPLOSION: • Do NOT drill into gas tank. • Verify the area is clear behind the mounting location before drilling. • After determining the mounting location for the remote socket, drill three holes and install. (see figure 3) • Once the remote socket is mounted, route the two bullet terminal wires back to where the control box will be mounted.
Step 5 - Handlebar Switch Assembly Handlebar mount assembly. Exact positioning may vary depending on ATV make and model. Use a test light to locate a suitable wire. Mini-rocker switch It is recommended that the switch be installed on the left handlebar.A piece of electrical tape around the handebar will help prevent rotation of mount on the handle bar. Do not tighten over any hoses or cables.
Check the System Before using the winch, verify the following: Wiring to all components is correct. All loose wires are tie wrapped tight. There are no exposed wiring or terminals. Cover any existing terminal exposures with terminal boots, heat shrink tubing or electricians tape. Turn ATV key switch to ON position. Check winch for proper operation. The wire rope should spool in and out in the direction indicated on the switch.
Planning and Use of Your Winch WARNING Read and understand all instructions and related Warnings, Cautions & Notices before attempting to install or use your Rugged Ridge® winch. 1. Ensure ATV/UTV, slope and conditions do not approach maximum rated pull. Leave a safety margin. Winch provides greater mechanical advantage when cable is fully extended. Plan pull using as much cable as practical. Double line using snatch block is preferred.
4. Plan your pull, recognizing recovery winches are not intended for continuous duty. Heavy load and slow line speed indicate high amperage draw causing heat build-up in motor. NOTICE Avoid damaging motor by adjusting to shorter pull cycles and longer cool-down periods under heavy load. Do not continue power to stalling motor. 5. Begin pull by gradually taking tension on cable to avoid shock loads. As you power in, cable must wind tightly and evenly on drum to prevent over-wraps and cable damage.
Troubleshooting NO. SYMPTOM POSSIBLE SUGGESTED • Insert Switch Assembly all the way into the connector. • Tighten nuts on all cable connections. • Tap solenoid to loosen contacts. Apply 12volts to coil terminals directly A clicking indicates proper activation. • Replace Switch Assembly • Check for voltage at armature port with Switch pressed. If voltage is present replace motor. • Allow to drain and dry. Run in short bursts without load until completely dry.
Winch Assembly Drawing 18
Winch Parts List No.
Specifications Extreme Heavy Duty 2.0 Specifications Rated line pull: 2000lbs (907kgs) single line Motor: Permanent magnetic DC 12V with (1.1hp)/0.82kw output Gear Train: Differential planetary Gear Ratio: 153 : 1 Wire Rope: 4mm x 15.2m (5/32"x50') Drum Size: 31.5mm x 72mm Dimensions: 285mm x 105mm x 105mm N.W: 6.5 kg (14.3 lbs) G.W: 9.5 kg Line speed and motor current (first layer) LBS Line Pull Line Speed Motor Current 0 500 1000 1500 2000 KGS 0 227 454 680 907 FPM 10.5 9.2 7.5 5.2 2.
Extreme Heavy Duty 2.5 Specifications Rated line pull: 2500lbs (1134kgs) single line Motor: Permanent magnetic DC 12V with (1.1hp)/0.82kw output Gear Train: Differential planetary Gear Ratio: 153 : 1 Wire Rope: 4.8mm x 15.2m (3/16"x50') Drum Size: 31.75mm x 72mm Dimensions: 300mm x 105mm x 105mm N.W: 7 kg (15.4 lbs) G.W: 10.5 kg Line speed and motor current (first layer) LBS Line Pull Line Speed Motor Current 0 1000 2000 2500 KGS 0 454 907 1134 FPM 10 7.1 3.3 2.6 MPM 3.0 2.15 1.3 0.
