Ramsey ATV REPLACEMENT MINI ROCKER SWITCH User Manual

Page 1
INSTALLATION INSTRUCTIONS FOR
REPLACEMENT MINI ROCKER SWITCH KIT #256129
FOR ATV WINCH WITH WIRELESS REMOTE SWITCH
WIRE SPLICE
YELLOW
WIRE
RED WIRE RED WIRE W/ WHITE STRIPE TO ACCESSORY WIRE ON VEHICLE IGNITION
BLACK MOTOR LEAD
RED WIRE
BLACK WIRE
GREEN WIRE
YELLOW WIRE
GREEN WIRE
GREEN WIRE
YELLOW WIRE
BLACK W/ YELLOW
STRIPE MOTOR LEAD
BLACK BATTERY LEAD
RED BATTERY LEAD
GREEN WIRE
WIRING HARNESS
BLACK WIRE TO GROUND
COAX CABLE
TOGGLE SWITCH
ROCKER SWITCH
MOTOR
BATTERY
SOLENOID
ASS'Y
ANTENNA
RECEIVER
TRANSMITTER
OUTIN
ON/OFF
E
A
B
C
Electrical Schematic
RAMSEY WINCH COMPANY
P.O. BOX 581510 TULSA, OK 74158-1510 USA
PHONE: (918) 438-2760 FAX: (918) 438-6888
visit us at http://www.ramsey.com
913404-0606-A
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Before Beginning Installation
1. Disconnect negative (-) battery cable from battery. Turn off vehicle ignition.
2. Disengage winch clutch.
3. Remove hood or cowling as necessary for easier access to installation area.
4. Locate accessory wire from vehicle ignition switch that is powered only when ignition is ON. Use this wire when splicing to Red wire on Rocker switch.
5. Make sure locations are close enough for wiring connections to be made without mak­ing alterations to wire lengths.
CAUTION: D
O NOT CONNECT NEGATIVE BATTERY
CABLE OR ENGAGE CLUTCH UNTIL INSTALLATION
IS COMPLETE
. W
INCH COULD BEGIN SPOOLING
CABLE UNEXPECTEDLY CAUSING INJURY OR
DAMAGE TO WINCH
.
Installing the Rocker Switch
For clarification, see wiring schematic on page 1.
1. Install green Wire Connector (item #1-
12) to green wire on Rocker Switch (item #2) and black Wire Connector (item #1-
13) to black wire on Rocker Switch, as shown at right.
2. The Rocker Switch assembly (item #2) will be assembled with the two halves of the housing already attached. Install the Mounting Bracket (item #1-2) using (2) #6 screws (item #1-4) and shake-proof washers (item #1-7). See figure below. Tighten securely. Do not overtighten.
3. Install (2) Handle Bar Clamps (item #1-
3) around ATV handle bars at a conven­ient location. Use a 3/4” long #10 screw (item #1-5) and #10 locknut (item #1-
9) to secure them. See figures below and at right. Secure loosely, do not tighten.
4. Install the Mounting Arm (item #1-1) to the Handle Bar Clamps using a 7/8” long #10 screw (item #1-6), shake-proof washer (item #1-8), and locknut (item #1-9). Install the shake-proof washer between the handle bar clamps and the mounting arm. See figures below. Do not tighten.
5. Install the Mounting Bracket (with rocker switch attached) to the Mounting Arm Bracket using a 3/4” long #10 screw, shake-proof washer, and locknut. Install the shake-proof washer between the mounting arm bracket and the mounting bracket.
1-2
2
1-7
1-4
NOTE:
LONGER SCREW
1-5
1-6
1-9
1-11
1-1
1-5
1-3
1-11
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6. Tighten all screws for the handle bar clamps and mounting brackets securely, positioning the rocker switch as desired.
7. Route the Rocker Switch wire
down the handle bars to where the solenoid is installed. Turn the han­dle bars fully right and left to ensure enough slack in the wire. Make sure wire is not drawn taut across any surface that could damage it. Use cable ties to anchor wire. Do not connect wires to solenoid yet.
8. Push ATV Accessory wire and red wire from switch into plastic splice (item #1-10). Fold splice clip over itself and snap closed.
Finish Installation
1. Unplug spade connectors from solenoid. Connect black wire from switch into right terminal (terminal above black with yel­low stripe motor lead). Connect green wire from switch into left terminal (termi­nal above black motor lead).
2. Plug the spade connectors for the exist­ing wireless remote into the “piggyback” plugs above the switch wires. Plug the yellow wire above the black switch wire and the green wire above the green switch wire. See below.
3. Confirm that winch clutch is disengaged.
4. Connect negative (-) battery cable to vehicle battery. Connect Black Battery Lead from winch to negative (-) vehicle battery terminal.
5. With ignition switch OFF, press Rocker switch to “OUT”—winch should not operate. If the winch does operate with the ignition off, confirm that proper accessory wire from ignition was spliced.
6. Spool a few feet of cable out by hand. Engage winch clutch. Turn ignition switch ON and press Rocker switch to “OUT”— winch should spool cable out. If winch does not operate with ignition on, check wiring against the schematic on page 1.
7. If winch spools cable IN instead of OUT, turn off ignition and reverse black and green wires on solenoid.
Black switch wire and yellow wire
Green switch wire and green wire
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Limited Lifetime Warranty
Ramsey Winch offers a limited lifetime warranty for each new Ramsey ATV winch against manufacturing defects in workman­ship and materials on all manufactured components.
Warranty registration cards for each winch must be submitted at the time of purchase, or within 90 days. Online registration of your winch is available at www.ramsey.com.
All Ramsey mounting kits and other accessories carry a 1- year limited warranty against defects in materials and workmanship.
This warranty is void if winch is used in commercial/industrial applications other than front mount self recovery.
Electrical components consisting of motors, solenoids, wiring, wire connectors, and associated parts carr y a limited 1-year warranty.
The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at the manufacturers facto­ry, or at a point designated by the manufacturer, of such part as shall appear to the manufacturer, upon inspection of such part, to have been defective in material or workmanship. This Warranty does not obligate Ramsey Winch Company to bear the cost of transportation charges in connection with the replacement or repair of defective parts, nor shall it apply to a product upon which repairs or alterations have been made, unless authorized by the manufacturer, or for equipment mis­used, neglected, or improperly installed.
Important notice: To the fullest extent permitted by appli­cable law, the following are hereby excluded and dis­claimed:
1. All warranties of fitness for a particular purpose;
2. All warranties of merchantability;
3. All claims for consequential or incidental damages. There are no warranties that extend beyond the descrip-
tion that appears on the face hereof. Some states do not allow the above exclusions or dis-
claimers in consumer transactions and as such this dis­claimer/exclusion may not apply to your particular case.
To the extent such warranties of fitness for a particular purpose or merchantability are deemed to apply to this product, they exist only for so long as the express limited warranty elsewhere set forth is in existence.
Ramsey Winch Company makes no warranty in respect to accessories, same being subject to the warranties of their respective manufacturers.
Ramsey Winch Company, whose policy is one of continuous product improvement, reserves the right to improve any prod­uct through changes in design or materials as it may deem desirable without being obligated to incorporate such changes in products of previous manufacture.
If field service at the request of the buyer is rendered and the fault is found not to be with Ramsey Winch Company’s prod­uct, the buyer shall pay the time and expense of the field repre­sentative. Bills for service, labor or other expenses which have been incurred by the buyer without express approval or authori­zation by Ramsey Winch Company will not be accepted.
This Warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.
3
8
1
5
4
9
6
2
7
1-Hardware Kit
2-Rocker Switch
12
10
13
PARTS LIST
ITEM
NO
. QTY. PART NO. DESCRIPTION
1 1 257560 HARDWARE KIT (see below) 2 1 282065 ROCKER SWITCH
Hardware Kit:
ITEM NO
. QTY. DESCRIPTION
1-1 1 Mounting Arm Bracket 1-2 1 Mounting Bracket 1-3 2 Handle Bar Clamp Bracket 1-4 2 Screw #6-32NC x 1/4”
Socket Head Black
1-5 2 Screw #10-24NC x 3/4” Truss
Cross Recess Black
1-6 1 Screw #10-24NC x 7/8” Truss
Cross Recess Black 1-7 2 Washer #6 Shake Proof 1-8 2 Washer #10 Shake Proof 1-9 3 Locknut #10-24NC Hex Black
1-10 1 Wire Splice 1-11 1 Cable Ties (pkg. of 12)
[not pictured]
1-12 1 Wire Connector (to green) 1-13 1 Wire Connector (to black)
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