Ramsey ATV 8 User Manual [en, de, es, fr]

OWNER'S MANUAL

Electric Winch Model ATV 8

with Push Button Remote Control Switch

English (Original Instructions) . . . . . . . . . . . . . . . 1

Français (Traduction des instructions originales) . . 10

Deutsch (Übersetzung der Originalanleitung) . . . . . 18

Español (Traducción de las instrucciones originales) 28

First Layer Line Pull 8kN (1800 lb) Noise Level 81 db

Ambient Temperature Range -28 to 60 C (-20F to 140F)

YER OF ROPE

Rated Line Pull Per Layer

Cumulative Rope Capacity Per Layer

Line Pull First Layer

Amp Draw 12V 31 72 101

* These specifications are based on recommended 5 mm (.196") 1960 grade wire rope

kN 8 6,6 5,3 4,8

lb 1,800 1,400 1,200 1,100

m 1,5 4,5 6 10,6

ft 5 15 20 37

kN No 2,6 5,3 lb Load 600 1,200 1800

1 2 3 4

Intended Purpose: Self recovery of vehicles and pulling of loads.

RAMSEY WINCH COMPANY

Post Office Box 581510 Tulsa, Oklahoma 74158-1510 USA

Phone: (918) 438-2760 Fax: (918) 438-6688

Visit us at http://ww.ramsey.com

6,6

135

WARNINGS: THE USER SHALL ENSURE THAT THE OPERATING PERSONNEL ARE GIVEN THE NECESSARY TRAINING. THE OPERATOR SHALL ALWAYS WORK IN COMPLIANCE WITH THE OPERATING INSTRUCTIONS. CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCH. DO NOT DISENGAGE CLUTCH UNDER LOAD. STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS. STAND CLEAR OF ROPE WHILE PULLING. DO NOT TRY TO GUIDE ROPE. DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PERSONNEL. A MINIMUM OF 2 WRAPS OF ROPE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD. AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR. EXCESSIVE “INCHING” SHALL BE AVOIDED.

Ramsey Authorized Representative in the Community:

(Please contact for regulatory inquiries only.)

Alura Group BV P.O. Box 18626

2502 EP The Hague

The Netherlands

Tel: (31) (0) 70 362-4896

Fax: (31) (0) 70 346-7299

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

OM-914220-1012-B

4707 N. Mingo Tulsa, Oklahoma 74117 (918) 438-2760

EC DECLARATION OF CONFORMITY

as defined by Machinery Directive 2006/42/EC

Here with we declare that winch model ATV 8 complies with the following directive provided that the USER complies with all responsibilities described in the Owner’s Manual:

2006/42/EC Applied harmonized standards: EN 14492-1:2006

Power-Driven Winches

ISO 9001:2000

Quality Management Systems Requirements

EC-KONFORMITÄTSERKLÄRUNG

gemäß Maschinenrichtlinie 2006/42/EC

Hiermit erklären wir, dass das Windenmodell ATV 8 der folgenden Richtlinie entspricht, sofern der BENUTZER alle Anweisungen im Benutzerhandbuch befolgt:

2006/42/EC Angewandte harmonisierte Normen: EN 14492-1:2006

Kraftgetriebene Winden ISO 9001:2000 Qualitätsmanagementsysteme Anforderungen

Ramsey Authorized Representative in the Community / Ramsey Représentant autorisé dans la comuauté / Ramsey Bevollmächtigter in der Europäischen Union / Ramsey Representante autorizado en la comunidad.

DÉCLARATION DE CONFORMITÉ EC

aux termes de la directive Machines 2006/42/EC

Nous déclarons par la présente que le modèle de treuil ATV 8 est conforme à la directive suivante, sous réserve que l’UTILISATEUR ait assumé toutes les responsabilités figurant dans le manuel de l’utilisateur :

2006/42/EC

Normes harmonisées appliquées : EN 14492-1:2006

Treuils motorisés

ISO 9001:2000

Systèmes de gestion de la qualité - Exigences

DECLARACIÓN EC DE CONFORMIDAD

según se define en la directiva de máquinas 2006/42/EC Con la presente declaramos que el modelo de cabestrante ATV 8 se halla en conformidad con la siguiente directiva siempre que el USUARIO cumpla todas las responsabilidades descritas en el Manual del propietario: 2006/42/EC Normas armonizadas aplicadas: EN 14492-1:2006

Cabestrantes accionados mecánicamente

ISO 9001:2000

Requisitos de los Sistema de gestión de la calidad

(Please contact for regulatory inquiries only. / Veuillez prendre contact uniquement pour des questions réglementaires.) (Bitte nur bei Regulierungsfragen kontaktieren. / Póngase en contacto sólo por cuestiones de reglamentación.)

Alura Group BV P.O. Box 18626 2502 EP The Hague The Netherlands

Tel: (31) (0) 70 362-4896

Fax: (31) (0) 70 346-7299

Serial Number / Numéro de série/ Seriennummer/ Número de Serie:_____________________

Signature / Signature / Unterschrift / Firma:

Todd Brady

Engineering Manager / Directeur technique/ Technischer Leiter/ Director de ingeniería

Date / Date / Datum / Fecha:

04-29-11

Contents

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .cover

User’s Responsibility for CE Compliance . . . . . . . . .2

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

Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . .4

End of Service Measures . . . . . . . . . . . . . . . . . . . . .4

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . .5

Winch Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . .7

Winch Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . .8

CE Declaration of Conformity . . . . . . . . . . . . . . . . . .9

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

load on the rope. Do not allow the rope to slip through your hand and do not approach the winch too closely.

I. Observe spooling of rope onto drum. Side pulls can

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

J. Neat, tight spooling avoids rope binding which is

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

User’s Responsibility for CE Compliance

1. Mount winch per Winch Installation Instructions.

2. Install the emergency stop switch per Installation Instructions included with the Emergency Stop Switch Kit.

3. Install 5 mm (.196 inch) grade 1960 wire rope. Maximum rope length of 10,6 M (37 ft) for four layers maximum.

4. Attach rope to the drum per Rope Installation Instructions.

5. Use a hook which includes a safety latch and has a minimum breaking strength of 20 kN.

Safety Precautions

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

the rope when pulling under load. B. Do not step over a rope, or near a rope under load. C. Use a heavy rag or gloves to protect hands from burrs

when handling winch rope. D. Modification, alteration, or deviation to the winch

should only be made by Ramsey Winch Company. E. 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. F. Disconnect the remote control switch from the winch

when not in use. G. Do not use winch in hoisting applications due to

required hoist safety factors and features.

Winch Installation

1. Tighten mounting bolts to 21,6 Nm (16 ft lb) 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 rope underwound as shown in the dimensional drawing on page 6.

CAUTION: Supplied 22,6 mm (.88 in) long mounting bolts with lockwashers are for a recommended winch mounting plate ness of 4,7 mm (.18 in). 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.

Operation

Rope Installation

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.

Note: Rope must be installed so that it feeds from the bottom of the drum.

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

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

Slide the rope through narrow end of the pocket against drum flange and wrap the rope around the anchor puck. Pull the rope 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.

Anchor Puck

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

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

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

Electrical Connections

End of Service Measures

For normal self-recovery work, your existing electrical system is adequate. Your battery should be kept in good condition. A fully charged battery and proper connections are essential.

The solenoid assembly reverses the direction of rope drum rotation.

CAUTION: BE SURE BATTERY CABLES ARE NOT DRAWN TAUT ACROSS ANY SURFACES WHICH COULD POSSIBLY DAMAGE THEM.

1. As shown on the schematic on the next page, con-

nect the red battery lead #13 and red lead from winch control solenoid to the E-stop solenoid.

2. Install emergency stop switch, solenoid, and rocker

switch per kit # 282067.

2. Connect the black battery lead to the negative (-) ter-

minal of the battery.

3. Connect the black motor lead to the #2 pole of the

motor.

When winch reaches the end of it’s serviceable life,

dispose of per local environmental regulations.

4. Connect the black with yellow stripe motor lead to

the #1 pole of the motor.

5. The remote switch plugs into the receptacle on the

solenoid.

The remote control switch is waterproof. It has push button stations on either side. It is designed this way to prevent quick winch reversals which can lead to solenoid failure. Make sure the motor has stopped fully before reversing. To actuate winch, plug remote control switch into the receptacle in the solenoid cover. Run winch forward and reverse to check connection and determine winch operating directions. Snap appropriate “IN” and “OUT” disc into proper thumb cavity. The switch is also color coded to aid you in not having to guess which direction your winch will run in. DO NOT LEAVE

SWITCH PLUGGED IN WHEN WINCH IS NOT IN USE.

ELECTRICAL SCHEMATICS

3 2 1

CAPACITOR

MOTOR

SWITCH

Rocker switch

in OFF position

YELLOW

(FROM E-STOP

SWITCH)

BLACK

RED

5 amp

FUSE

GROUND

WIRE SPLICE

TO VEHICLE

IGNITION

BLACK MOTOR

LEAD

BLACK W/ YELLOW

STRIPE MOTOR LEAD

RED

LEAD

YELLOW

(FROM E-STOP

SWITCH)

(GROUND)

E-STOP

SOLENOID

BATTERY

E-STOP

SWITCH

RED (#13)

BLACK

BATTERY LEAD

WINCH

CONTROL

SOLENOID

Winch Mounting

WARNING

LINE UNDER TENSION

CLUTCH WITH WINCH

DO NOT DISENGAGE

4.83

122,7

3.00 76,2

4.50

114,3

Ø3.00

76,2

5.80

147,4

4.88

124,0

DRUM

CABLE SPOOLS

"IN" UNDER DRUM

4.40

111,8

13.19 335,0

2.97 75,4

Ø1.75

44,4

5/16-18 NC

4 Places

*Mounting Hole P

attern

Four 11/32” (8,6 mm) diameter holes on 4.88” (124 mm) x 3.00” (76,2 mm) pattern

Solenoid Mounting

Cable must exit under the drum

*Mounting Hole P

attern

Three 9/32” (7,1 mm) diameter holes on 4.75” (120,7 mm) x

4.13” (104,9 mm) pattern

Note: Allow sufficient clearance next to receptacle to plug remote switch into.

TROUBLESHOOTING

Defective remote switch plug

MOTOR RUNS IN ONLY

ONE DIRECTION

Defective solenoid or stuck sole

noid

MOTOR RUNS EXTREMELY HOT Long period of operation Cooling-off periods are essential to pre-

Insufficient battery.

MOTOR RUNS, BUT WITH INSUFFICIENT POWER OR

WITH LOW LINE SPEED

Bad connection

Insufficient charging system

Disengage winch clutch, remove remote control switch from the socket and jump pins at 8 and 4 o'clock. Motor should run. Jump pins at 8 and 10 o'clock. Motor should run.

Jar solenoid assembly to free contacts. Check each solenoid by applying +12 volts to coil-terminal (it should make an audible click when energized).

vent overheating.

Test for faulty vehicle battery

Check battery cable for corrosion; clean and grease. Replace with larger capacity charging system.

MOTOR RUNS, BUT DRUM

DOES NOT TURN

MOTOR WILL NOT OPERATE

MOTOR WATER DAMAGED

Clutch not engaged if clutch engaged but symptoms still

exist, it will be necessary to disassemble winch to determine cause and repair.

Defective solenoid or stuck solenoid.

Defective remote switch plug.

Defective motor.

Loose connections

Submerged in water or water from high pressure car wash.

Jar solenoid assembly to free contacts. Check each solenoid by applying +12 volts to coil-terminal (it should make an audible click when energized).

Disengage winch clutch, remove remote control switch from the socket and jump pins at 8 and 4 o'clock. Motor should run.

If solenoids operate, check for voltage at armature post; replace motor.

Check all electrical connections from the battery to the motor.

Allow to drain and dry thoroughly, then run motor without load in short bursts to dry windings.

ATV 8 PARTS

INTENDED PURPOSE: VEHICLE RECOVERY AND PULLING OF LOADS.

READ OPERATING INSTRUCTIONS BEFORE USE FOR WARNINGS,

INSTALLATION AND OPERATING INSTRUCTIONS.

434577

MODEL: ATV 8

WIRE ROPE MIN. BREAKING STRENGTH: 16 kN

MAX. ROPE DIA: 5 mm

MAX LAYERS: 4 (10 M OF 5 mm ROPE)

NOT

SHOWN

ATV 8 PARTS LIST

ITEM NO. QTY. PART NO. DESCRIPTION

1 1 251110 REMOTE SWITCH ASSY 2 1 251191 CLUTCH KIT 3 1 251192 CABLE DRUM KIT 4 1 251195 BUSHING KIT 5 1 251196 TIE BAR KIT 6 1 251213 CLUTCH END GEAR KIT 7 1 251286 MOTOR KIT 8 1 251234 SOLENOID ASSEMBLY

9 1 251287 MOTOR END GEAR SET 10 1 251248 SOLENOID MOUNTING KIT 11 1 256116 BRAKE KIT 12 1 289197 72" BLACK BATTERY LEAD 13 1 289199 72" RED BATTERY LEAD 14 1 289203 48" BLACK MOTOR LEAD 15 1 289204 48" BLACK W/ YELLOW STRIPE MOTOR LEAD 16 1 422023 HAWSE FAIRLEAD 17 1 282067 E-STOP SWITCH KIT (NOT SHOWN) 18 1 434574 NAME AND DATA TAG 19 1 434577 WARNING TAG

GUIDE DE L'UTILISATEUR

Treuil électrique modèle ATV 8 avec commutateur

de commande à distance à bouton-poussoir

English (Original Instructions) . . . . . . . . . . . . . . . 1

Français (Traduction des instructions originales) . . 10

Deutsch (Übersetzung der Originalanleitung) . . . . . 18

Español (Traducción de las instrucciones originales) 28

Traction du câble, première couche 8 kN (816,47 kg) Niveau sonore 81 dB

Plage de température ambiante -28 à 60 °C

COUCHE DE CÂBLE 1 2 3 4

Traction nominale par couche de câble

Capacité cumulative de câble par couche

Traction du câble, première couche

Intensité du moteur 12V 31 72 101

* Ces caractéristiques sont basées sur l'utilisation du câble métallique recommandé de 5 mm de calibre 1960

kN 8 6,6 5,3 4,8

lb 1,800 1,400 1,200 1,100

m 1,5 4,5 6 10,6

ft 5 15 20 37

kN À 2,6 5,3

lb vide 600 1,200 1800

6,6

135

AVERTISSEMENTS : L'UTILISATEUR DOIT VEILLER À CE QUE TOUT OPÉRATEUR REÇOIVE LA FORMATION NÉCESSAIRE. L'OPÉRATEUR DOIT TOUJOURS TRAVAILLER EN CONFORMITÉ AVEC LES INSTRUCTIONS D'UTILISATION. L'EMBRAYAGE DOIT ÊTRE COMPLÈTEMENT ENCLENCHÉ AVANT DE DÉMARRER LE TREUIL. NE JAMAIS RELÂCHER L'EMBRAYAGE EN PRÉSENCE D'UNE CHARGE. NE JAMAIS SE PLACER SOUS UNE CHARGE SOULEVÉE NI À PROXIMITÉ. RESTER À L'ÉCART DU CÂBLE LORS DU TREUILLAGE. NE PAS ESSAYER DE GUIDER LE CÂBLE. NE PAS UTILISER LE TREUIL POUR SOULEVER, MAINTENIR OU TRANSPORTER DES PERSONNES. IL CONVIENT DE CONSERVER AU MINIMUM DEUX TOURS DE CÂBLE AUTOUR DU TAMBOUR POUR MAINTENIR LA CHARGE. ÉVITER TOUTE SITUATION DE DÉPLACEMENT DE LA CHARGE OU D'À-COUPS. ÉVITER LES MOUVEMENTS SACCADÉS.

Utilisation prévue : autodépannage de véhicules et traction de charges.

RAMSEY WINCH COMPANY

Post Office Box 581510 Tulsa, Oklahoma 74158-1510 USA

Phone: (918) 438-2760 Fax: (918) 438-6688

Visit us at http://ww.ramsey.com

Ramsey Représentant autorisé dans la comuauté

(Veuillez prendre contact uniquement pour des questions réglementaires.)

Alura Group BV P.O. Box 18626

2502 EP The Hague

The Netherlands

Tel: (31) (0) 70 362-4896

Fax: (31) (0) 70 346-7299

MISE EN GARDE : S'ASSURER DE LIRE ET DE COMPRENDRE CE MANUEL AVANT D'INSTALLER ET D'UTILISER LE TREUIL. PRENDRE CONNAISSANCE DES CONSIGNES DE SÉCURITÉ.

OM-914220-1012-B

4707 N. Mingo Tulsa, Oklahoma 74117 (918) 438-2760

EC DECLARATION OF CONFORMITY

as defined by Machinery Directive 2006/42/EC

Here with we declare that winch model ATV 8 complies with the following directive provided that the USER complies with all responsibilities described in the Owner’s Manual:

2006/42/EC Applied harmonized standards: EN 14492-1:2006

Power-Driven Winches

ISO 9001:2000

Quality Management Systems Requirements

EC-KONFORMITÄTSERKLÄRUNG

gemäß Maschinenrichtlinie 2006/42/EC

Hiermit erklären wir, dass das Windenmodell ATV 8 der folgenden Richtlinie entspricht, sofern der BENUTZER alle Anweisungen im Benutzerhandbuch befolgt:

2006/42/EC Angewandte harmonisierte Normen: EN 14492-1:2006

Kraftgetriebene Winden ISO 9001:2000 Qualitätsmanagementsysteme Anforderungen

DÉCLARATION DE CONFORMITÉ EC

aux termes de la directive Machines 2006/42/EC

2006/42/EC

Normes harmonisées appliquées : EN 14492-1:2006

Treuils motorisés

ISO 9001:2000

Systèmes de gestion de la qualité - Exigences

DECLARACIÓN EC DE CONFORMIDAD

Cabestrantes accionados mecánicamente

ISO 9001:2000

Requisitos de los Sistema de gestión de la calidad

(Veuillez prendre contact uniquement pour des questions réglementaires.)

Alura Group BV P.O. Box 18626 2502 EP The Hague The Netherlands Tel: (31) (0) 70 362-4896 Fax: (31) (0) 70 346-7299

Serial Number / Numéro de série/ Seriennummer/ Número de Serie:_____________________

Signature / Signature / Unterschrift / Firma:

Todd Brady

Engineering Manager / Directeur technique/ Technischer Leiter/ Director de ingeniería

Date / Date / Datum / Fecha:

04-29-11

+ 25 hidden pages