Ramsey ATV 1800T User Manual

Ramsey Winch Company

OWNER'S MANUAL

ATV Electric Winch Model ATV1800T

Congratulations

You have purchased the finest winch available in its service class. It features a highly efficient 3 stage planetary gear set which transmits torque from a permanent magnet motor. A safe positive clutch allows free spooling for quick cable deployment. Your Ramsey winch was designed and manufactured to provide you with the utmost in utility. As with any device that combines power and movement in its use, there are dangers if improperly used.

At the same time, there are easier and faster ways for

getting the job done if certain precautions are taken first. Please read this manual carefully. It contains useful ideas in obtaining the most efficient operation from your Ramsey Winch and safety procedures you need to know before beginning use. When you follow our guidelines for operation, your Ramsey winch will give you many years of satisfying service. Thank you for choosing Ramsey. You will be glad you have one working for you.

Intended Purpose for Ramsey ATV 1800T Series Winch: Self recovery of vehicles, pulling of loads.

CAUTION: Read and understand this manual before installation and operation of winch. See Safety Precautions.

* CABLE MUST BE UNIFORMLY WOUND ONTO DRUM.

815

1,800

2.12

ATV1800T WINCH

LAYER OF CABLE

3.7

101

544

1,200

4.2

272

600

19.1

5.8

LOAD

12.2

13.8

135

9.2

2.8

816

1,800

11.3

498

1,100

4.56

680

1,500

7.6

544

1,200

15.2

453

1,000

(lbs) (kgs)

Rated line pull per layer

Cumulative cable capacity per layer

(ft)* (m)*

Line pull

(lbs) (kgs)

Line speed

(fpm)

(mpm)

Amp draw

(12v)

first layer

(5 mm dia. cable)

Noise Level: 81 dB(A)

Safety Precautions To Guard Against

Possible Injury.....

A. Keep yourself and others a safe distance to the side

of the cable when pulling under load. B. Do not step over a cable, or near a cable under load. C. Use supplied hook strap when handling hook for

spooling wire rope. D. Do not use ATV to pull a load on the winch cable.

This could result in cable breakage and/or winch

damage E. Use a heavy rag or gloves to protect hands from

burrs when handling winch cable. F. Apply blocks to wheels when ATV is on an incline. G. Winch clutch should be disengaged when winch is

not in use and fully engaged when in use. H. Modification, alteration, or deviation to the winch

should only be made by Ramsey Winch Company.

I. Keep the duration of your pulls as short as possible.

If the motor becomes uncomfortably hot to the touch, stop and let it cool for a few minutes. Do not pull more than one minute at or near the rated load. Do not maintain power to the winch if the motor stalls. Electric winches are for intermittent usage and should not be used in constant duty applications.

J. Disconnect the remote control switch from the

winch when not in use. A safety ON-OFF switch on your ATV is required.

K. Do not use winch in hoisting applications due to

required hoist safety factors and features.

L. To respool correctly, it is necessary to keep a slight

load on the cable. Do not allow the cable to slip through your hand and do not approach the winch too closely. When all the cable except a few feet is in, stop and finish spooling in cable by rotating the drum by hand with clutch disengaged. Always use hook strap to hold hook when spooling.

Tips for Safe Operation

Don't underestimate the potential danger in winching operations. Neither should you fear them. Do learn the basic dangers and avoid them.

Observe spooling of cable onto drum. Side pulls can cause cable to pileup at one end of the drum. To correct uneven stacking, spool out that section of the cable and move it to the other end of the drum and continue winching. Uneven spooling which causes cable pileup can interfere with the winch tie rods causing damage to the winch.

Never connect the hook back to the cable. This causes cable damage. Always use a sling or chain of suitable strength.

Observe your winch while winching. If possible, while standing at a safe distance. If you use ATV drive to assist, stop and get off every few feet to assure the cable is not piling up in one corner. Jamming cable can break your winch.

Contents

Performance Specifications . . . . . . . . . . . . . . . .cover

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . .2

Tips for Safe Operation . . . . . . . . . . . . . . . . . . . . . .2

Techniques of Operation . . . . . . . . . . . . . . . . . . . . . .3

General Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3

Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Manual Control Switch Operation . . . . . . . . . . . . . . .4

Electrical Connections and Operations . . . . . . . . . . .5

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . .6

Winch Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Solenoid Mounting . . . . . . . . . . . . . . . . . . . . . . . . . .7

Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . .8

Winch Parts List (Manual Switch) . . . . . . . . . . . . . .9

Winch Parts List (Remote Switch) . . . . . . . . . . . . .10

Warranty . . . . . . . . . . . . . . . . . . . . . . . . .back cover

Do not attach tow hooks to winch mounting apparatus. They must attach to ATV frame.

When double lining during stationary winching, the winch hook should be attached to the chassis of the ATV. Since the greatest pulling power is achieved on the innermost layer of your winch, it is desirable to pull off as much line as you can for heavy pulls. If this is not practical, use a snatch block and double line arrangement.

Neat, tight spooling avoids cable binding which is caused when a load is applied and the cable is pinched between two other wraps of cable. If this happens, alternately power the winch in and out a few inches. Do not attempt to work a bound cable under load, free by hand.

Techniques of Operation

The best way to get acquainted with how your winch operates is to make a few test runs before you actually need to use it. Plan your test in advance. Remember you hear your winch as well as see it operate. Get to recognize the sound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Soon you will gain confidence in operating your winch and its use will become second nature with you.

Your winch will not only pull your ATV up or ease your ATV down a steep grade, it will also pull another ATV or a load while your ATV is anchored in a stationary position.

When pulling a heavy load, place a blanket, jacket or tarpaulin over the cable five or six feet from the hook. It will slow the snap back in the event of a broken cable.

Use the ATV wheel power to help the winch, but don'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 possibilities as well as leverage situations, direction, and goal.

General Installation

The winch shown in this owner’s manual is solely and exclusively designed for ATV mounted, non-industrial applications. All other applications will void warranty.

1. Install Winch and Mounting Kit according to instructions supplied with Mounting Kit. Tighten mounting bolts to 16 ft-lbs (21.6 Nm) torque.

2. Do not attach motor and battery leads until instructed to do so.

3. It is very important that the winch be mounted

on a flat surface, with the cable underwound as shown in the dimensional drawing on page 7.

CAUTION: Supplied 7/8” long mounting bolts with lockwashers 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.

Winches equipped with cable guide fairleads can pull from several directions. Pull from an angle only to straighten up the ATV--otherwise you can damage structural members or other parts of your ATV and cause excess cable buildup on one end of the winch drum.

For basic self-recovery, anchor to a tree or heavy rock. When anchoring to a tree, always use a tree trunk protector.

Winch Operation

The winch clutch allows rapid unspooling of the wire rope for hooking onto the load or anchor point. The clutch is operated by the shifter located on the end of the winch as follows:

1. To disengage the clutch, turn the clutch shifter to the "FREESPOOL" position. When the clutch is in FREESPOOL, the arrow on the clutch knob will point to FREESPOOL on the decal on the winch. Wire rope may now be freespooled off the drum.

2. To engage the clutch, turn the clutch shifter to the "ENGAGED" position. When the clutch is in ENGAGED position, the arrow on the clutch knob will point to ENGAGED on the decal on the winch. The winch is now ready for pulling.

Your battery must be kept in good condition. A fully charged battery and proper connections are essential. Run the vehicle engine during winching operations to keep battery charged.

Maintenance

Corrosion on electrical connections will reduce performance or may cause a short. Clean all connections. In salty environments use a silicone sealer to protect from corrosion.

All moving parts in the winch are permanently lubricated with broad temperature range lithium based grease.

Lubricate cable periodically using light penetrating oil. Inspect for broken strands and replace if necessary. If the cable becomes worn or damaged, it must be replaced.

Cable Installation

Note: Cable should be installed so that it feeds from the bottom of the drum.

Unwind the new cable by rolling it out along the ground to prevent kinking. Remove old cable and observe the manner in which it is attached to the cable drum flange, watching carefully for the cable anchor puck.

Before installing the new cable assembly, securely wrap the end of the cable with tape to prevent fraying.

Slide the cable through narrow end of the pocket against drum flange and wrap the cable around the anchor puck. Pull the cable and anchor back into the wide end of the pocket leaving approximately 1/8” beyond edge of pocket as shown. Use a hammer and drift punch to drive the back side of the wire rope, firmly seating the wire rope and anchor into the pocket.

Wind on the cable by pulling in a light load to keep the tension constant. Allow the cable to swivel by using a length of chain or a swivel block between the cable hook and the load.

Manual Control Switch Operation

The manual control switch assembly is attached to the motor power terminals. Rotation of the switch clockwise spools cable “in” and counterclockwise spools cable “out”.

The short end of the cable should extend approximately 1/8” beyond the top edge of pocket.

+ 8 hidden pages