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Rugged Ridge Extreme Heavy Duty 2.0 Owner's Manual

Extreme heavy duty atv/utv recovery winch
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Extreme Heavy Duty
ATV/UTV Recovery Winch
2.0
-
2.5
Owners
Manual

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Summary of Contents for Rugged Ridge Extreme Heavy Duty 2.0

  • Page 1 ® Extreme Heavy Duty ATV/UTV Recovery Winch Owners Manual...
  • Page 2 ATV/UTV. Each winch operation may involve different risks making it impractical to provide warnings or information regarding all the risks you may encounter. Fully understand your Rugged Ridge instructions and practice safe ®...

  • Page 3: Table Of Contents

    Planning and Use of Your Winch ........15 Troubleshooting ............17 Winch Assembly Drawing ..........18 Winch Parts List ............19 Specifications ..............20 Extreme Heavy Duty 2.0 ..........20 Extreme Heavy Duty 2.5 ..........21 Winch Packing List DESCRIPTION QUANTITY 1. Winch Assembly with Wire Rope ......1 2.

  • Page 4: Safety Warnings & Precautions

    (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 severe injury or death.
  • Page 5 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. •...
  • Page 6 • 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.
  • Page 7 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.
  • Page 8 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.

  • Page 9: Winch Assembly & Mounting (2.0 Model)

    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.

  • Page 10: Winch Assembly & Mounting (2.5 Model)

    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.

  • Page 11: Mount Control Box

    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.

  • Page 12: Mount Connector For Remote

    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.

  • Page 13: Handlebar Switch Assembly

    Step 5 - Handlebar Switch Assembly Handlebar mount assembly. Exact Mini-rocker switch positioning may vary depending on ATV make and model. 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.

  • Page 14: Check The System

    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.

  • Page 15: Planning And Use Of Your Winch

    Planning and Use of Your Winch Read and understand all instructions and related Warnings, Cautions WARNING & Notices before attempting to install or use your Rugged Ridge winch. ® 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.
  • Page 16 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. Avoid damaging motor by adjusting to shorter pull NOTICE cycles and longer cool-down periods under heavy load. Do not continue power to stalling motor.

  • Page 17: Troubleshooting

    Troubleshooting SYMPTOM POSSIBLE SUGGESTED • Insert Switch Assembly all • Switch the way into the connector. Assembly not • Tighten nuts on all cable connected connections. property • Tap solenoid to loosen • Loose contacts. Apply 12volts battery cable to coil terminals directly A Connections clicking indicates proper Motor does...

  • Page 18: Winch Assembly Drawing

    Winch Assembly Drawing...

  • Page 19: Winch Parts List

    Winch Parts List Description Motor Stationary Gear Housing Assembly Gear Carrier Assembly T-Series Rotator Gear Drum Support Plate Spring Washer 4 & Pan Head Screw M4 X 12 Drum Support Bushing Clutch Assembly Spring Drum Assembly Screw M5 X 5 T-Series Bushing Thick Flat Washer Hex Flange Nut M5...

  • Page 20: Specifications

    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)

  • Page 21: Extreme Heavy Duty 2.5

    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...

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Extreme heavy duty 2.5

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