Ramsey ATV-3000 User Manual

Ramsey Winch Company

OWNER'S MANUAL

ATV Electric Winch

Model ATV3000

* CABLE MUST BE UNIFORMLY WOUND ONTO DRUM.

1,350

3,000

2.12

ATV3000 WINCH

20.8

6.3

LOAD

LAYER OF CABLE

(3/16"-4.8 mm- dia. cable)

3.8

680

1,500

4.5

453

1,000

17.6

5.3

227

500

12.315

10.2

3.0

906

2,000

11.3

857

1,890

4.56

1,133

2,500

7.6

952

2,100

15.2

761

1,680

(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)

2,500 1133

8.5

2.6

121

first layer

3,000 1360

5.0

1.5

150

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

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.

Please Note: Ramsey ATV 3000 winches are designed for ATV use. The winches are not designed 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 makes a separate, complete line of winches for industrial/commercial use. Please contact the factory for further information.

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 the 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. Do not use winch in hoisting applications due

to required hoist safety factors and features.

K. Do not exceed maximum line pull ratings

shown in tables. Shock loads must not exceed these ratings.

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.

Store the wireless remote control transmitter in a safe place where it will not become damaged. Inspect it before you use it.

When ready to begin winching, push and hold the On/Off button on the transmitter until it flashes. Do not engage clutch with motor running.

Never connect the hook back to the cable. This

Contents

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

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

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

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

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

Rotating the Motor . . . . . . . . . . . . . . . . . .4-7

Operating Instructions . . . . . . . . . . . . . . . . .8

Maintenance . . . . . . . . . . . . . . . . . . . . . . . .8

Cable Installation . . . . . . . . . . . . . . . . . . . . .8

Wireless Remote Control Operation . . . . . . .8

Trouble Shooting Guide . . . . . . . . . . . . . . . .9

Winch Parts List (Wireless Remote) . . .10-11 Electrical Schematic (Wireless Remote) . . .11

Rocker Switch Operation . . . . . . . . . . . . . .12

Rocker Switch Installation . . . . . . . . . .12-14

Electrical Schematic (Rocker Switch) . . . .13

Winch Parts List (Rocker Switch) . . . . .14-15

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

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.

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, nonindustrial 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 torque.

2. It is very important that the winch be

mounted on a flat surface, with the cable feeding 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 until instructed to do so.

4. Refer to installation instructions for the Wireless Remote Switch (in the ATV Wireless Installation and Operation Manual) for installation of the switch and electrical assemblies for the winch.

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

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.

Rotating the Motor on your ATV Winch

The ATV winch has the motor studs and leads positioned on the end of the motor aligned vertically. If you need to rotate the motor on your ATV winch to gain clearance, you can rotate the motor 90°. The motor studs will then be aligned horizontally.

Before you begin:

Note: If you have installed the optional Brake kit (P/N 256116) for the ATV winch, make sure you have the Brake kit installation instructions before proceeding. You will need to re-install the Brake kit after you rotate the motor (step 6 on the following pages). Contact Ramsey if you do not have your installation instructions.

1. Remove the cable from the drum. Turn the clutch handle to Freespool and pull cable off. Slide the end of the cable out of the pocket next to the drum flange until the cable anchor can be removed. Be sure to keep the cable anchor for re-installing the cable. Leave the clutch 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 bars from between end bearings.

2. Lift the motor end off the drum and set down with the motor end down. Make sure the shaft, drum bushing and spring stay with the drum.

3. Remove the bolts that hold the end plate to the motor end housing. Lift off the end plate and take the nuts and washers out of the mounting feet. Set aside the gear assemblies and bushing. The input sun and planetary gear carrier may come out together.

4. Lean the motor end and loosen the motor tie bolts off the tie bolt nuts. Lean the motor end back up so that it is sitting upright. Do not let

the motor end cap come apart from the rest of the motor. Lift the motor end housing

and rotate 90°. Put the tie bolt nuts in the other set of pockets and carefully lean the motor end back. Tighten the tie bolts to 45-50 in-lbs. torque. Do not overtighten.

5. After rotating the motor, the motor end will appear as shown at right. The motor studs will be aligned horizontally, and the motor tie bolt nuts will be in the other set of pockets.

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