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Related Manuals for Rugged Ridge Extreme Heavy Duty 3.0
Summary of Contents for Rugged Ridge Extreme Heavy Duty 3.0
- 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 ®...
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Page 3: Table Of Contents
Winch Maintenance ............14 Planning and Use of Your Winch .........15 Troubleshooting ............17 Winch Assembly Drawing ..........18 Winch Parts List ............19 Specifications ..............20 Extreme Heavy Duty 3.0 ..........20 Extreme Heavy Duty 3.5 ..........21 Extreme Heavy Duty 4.5 ..........22 Winch Packing List DESCRIPTION QUANTITY 1. -
Page 4: Safety Warnings & Precautions
(line speed & pull) for your model winch are set out on pages 20-22 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.
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Page 9: Installation
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 (Figure 1) 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. -
Page 10: Mount The Control Box
Figure 1: Orientation of winch to mounting plate and bolt lengths Step 2 - Mount the Control Box (Figure 2) 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 11: Mount The Handlebar Switch
Step 3 - Mount the Handlebar Switch TO PREVENT SERIOUS INJURY OR DEATH FROM ELECTICAL FIRE: • Do NOT route electrical cables across sharp edges. • Do NOT route electrical cables through or near moving parts. • Do NOT route electrical cables through or near any high heat parts. • Avoid pinch and wear/abrasion points when installing all electrical cables. -
Page 12: Mount The Connector For Remote
Step 4 - 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 & Remote Option Wiring installation diagram • Always remove jewelry and wear eye protection. • Never lean over battery while making connections. • Always verify area is clear of fuel lines, fuel tank, brake lines, electrical wires, etc. When drilling. •...
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Page 14: Check The System
Step 6 - Check the System Figure 7 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.
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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 Gasket Bearing Bearing Bushing Drum Support, Motor Brake Base Spring Brake Gear Sliding Bushing Bushing for Water Proof Tie Rod O-Ring for Water Proof Washer 8 Hex Head Screw M5*20 Drum Assembly Hex Head Screw M5*15 Gear Box Cover Shaft Gear Carrier Assembly, Stage 3... -
Page 20: Specifications
Specifications Extreme Heavy Duty 3.0 Specifications Rated line pull: 3000lbs (1360kgs) single line Motor: Permanent magnetic DC 12V with (1.3hp)/1.0kw output Gear Train: 3 stage planetary Gear Ratio: 138 : 1 Wire Rope: 4.8mm x 15.2m (3/16" x 50') Drum Size: 50mm x 76.5mm... -
Page 21: Extreme Heavy Duty 3.5
Extreme Heavy Duty 3.5 Specifications Rated line pull: 3500lbs (1587kgs) single line Motor: Permanent magnetic DC 12V with (1.5hp)/1.1kw output Gear Train: 3 stage planetary Gear Ratio: 198 : 1 Wire Rope: 5.5mm x 15.2m (7/32"x49') Drum Size: 50mm x 76.5mm Dimensions: 334mm x 114mm x 120mm Bolt Pattern: 124mm x 76mm N.W: 8.0kgs (17.6lbs) -
Page 22: Extreme Heavy Duty 4.5
Extreme Heavy Duty 4.5 Specifications Rated line pull: 4500lbs (2041kgs) single line Motor: Permanent magnetic DC 12V with (2.0hp)/1.2kw output Gear Train: 3 stage planetary Gear Ratio: 198 : 1 Wire Rope: 6mm x 13.7m (6/25"x45') Drum Size: 50mm x 76.5mm Dimensions: 334mm x 114mm x 120mm Bolt Pattern: 124mm x 76mm N.W: 8.6kgs (19lbs) - Page 23 Notes...
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