Rugged Ridge Extreme Heavy Duty 3.0 Manuel utilisateur
Owners
Manual
®
Extreme Heavy Duty
ATV/UTV Recovery Winch
3.0 - 3.5 - 4.5
2
Your Rugged Ridge® ATV/UTV recovery winch is a powerful tool adding
considerable utility and enjoyment to your off road ATV/UTV. Keep in mind,
however, that your ATV/UTV’s weight, the forces required for ATV/UTV recovery
and the variety of terrain, grades and cable rigging your might encounter, result in
any winching operation having the potential for serious personal injury or damage
to your winch or 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
winch operations before attempting an actual ATV/UTV recovery.
To reduce winch related risks and help you make informed decisions about
safety, the accompanying instructions provide certain information in the form of
“Warnings”, “Cautions” and “Notices”. This information alerts you to potential
hazards that could hurt you or others.
This is a caution against anything which may cause damage to your
winch, the ATV/UTV or its equipment if the caution is ignored. The Notice includes
information about how you can avoid or reduce those risks.
This is a signal telling you that you or others CAN be KILLED
or SERIOUSLY HURT if you don’t follow the Warning. The Warning includes
information about what you must or must not do in order to reduce the risk of
injury to yourself and others.
This is a signal telling you that you or others CAN be HURT if you
don’t follow the instruction. The Caution includes information about how you can
avoid those risks.
®
A FEW WORDS ABOUT PRODUCT SAFETY
ATV/UTV RECOVERY ELECTRIC WINCH USE & INSTALLATION INSTRUCTIONS
CABLE ENTANGLEMENT/PINCH/CRUSH HAZARDS
Failure to follow these instructions could lead to severe injury or death. Consult
further WARNINGS/CAUTIONS and instructions in this use/installation manual.
Due to loads involved, all winching involves significant risks. To minimize risks
of injury Always:
• Assure winch, mounting, cable and hook are undamaged. ATV/UTV, slope and
conditions should not approach maximum rated pull. Leave a safety margin.
• Use supplied hook strap when spooling in or out (no load). Use gloves and
keep fingers and body clear of hook, cable and fairlead
during installation and all winch operations.
• Position operator away from line of cable. Keep others at a safe right angle
from cable and ATV/UTV when winching (min. 1.5 times distance of cable). Use
greatest cable length possible while keeping at least five turns around spool.
• Fully engage clutch before powering cable in. Do no disengage or adjust
clutch while under load. Pull in stages to avoid heat buildup and motor
damage.
• Never use ATV/UTV recovery winch for persons or as hoist.
!
WARNING
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Winch Packing List .......................................................03
Safety Warnings & Precautions ....................................04
Installation .....................................................................09
Mount the Winch ..........................................................09
Mount the Control Box ................................................10
Mount the Handlebar Switch .......................................11
Mount the Connector for Remote ..............................12
Install the Wiring ..........................................................12
Check the System .........................................................14
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
Table of Contents:
DESCRIPTION QUANTITY
1. Winch Assembly with Wire Rope ...........................1
2. Cap Bolt M8* 30 .......................................................2
3. Lock Washers ...........................................................2
4. Flat Washers ..............................................................2
5. M8 Nuts .....................................................................2
6. Clevis Hook w/Pin ...................................................1
7. Power Cord/Switch Assembly ...............................1
8. Strap ..........................................................................1
9. Mounting Plate ...........................................................1
Winch Packing List
4
Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to severe injury or
death. To avoid injury to hands or fingers:
• Always keep hands clear of rope, hook loop, hook and fairlead
opening during installation, operation and when spooling in or
out.
• Always use extreme caution when handling hook and rope
during spooling operations.
• Always use supplied hook strap whenever spooling rope in or
out, during installation, and during operation.
• Always keep ATV/UTV in sight during winching operation.
• Always wear heavy leather gloves when handling rope.
Chemical and Fire Hazard
Failure to observe these instructions could lead to severe injury or
death.
• 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.
• Never route electrical cables:
»Across any sharp edges.
»Through or near moving parts.
»Near parts that become hot.
• Always insulate and protect all exposed wiring and electrical
terminals.
Installing Your Winch
Take a moment to read and understand all instructions and safety
information before attempting installation or use of your Rugged
Ridge® ATV/UTV recovery winch. Specifications and sample
performance (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.
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.
• Never leave remote control where it can be activated during
freespooling, rigging, or when the winch is not being used
• Always require operator and bystanders to be aware of ATV/
UTV and or load.
Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to minor or
moderate injury.
General Safety:
• Always know your winch. Take time to fully read the Installation
Guide and the Basic Guide to Winching Techniques in order to
understand your winch and its operation.
• Never operate this winch if you are under 16 years of age.
• Never operate this winch when under the influence of drugs,
alcohol or medication.
• Never exceed winch or rope capacity listed on product data
sheet. Double line using a snatch block to reduce winch load
Installation Safety:
• Always choose a mounting location that is sufficiently strong to
withstand the maximum pulling capacity of your winch.
• Always use factory approved mounting hardware, components,
and accessories.
• Always use grade 5 (grade 8.8 metric) or better mounting
hardware.
• Never weld mounting bolts.
• Always use care when using longer bolts than those supplied
from factory. Bolts that are too long can damage the base and/
or prevent the winch from being mounted securely.
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Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to minor or
moderate injury.
• Always inspect, rope, hook, and slings before operating winch.
Frayed, kinked or damaged rope must be replaced immediately.
Damaged components must be replaced before operation.
Protect parts from damage.
• Never leave remote control plugged into winch when free
spooling, rigging, or when the winch is not being used.
• Never hook rope back onto itself. This damages the rope.
• Always use a choker chain, choker rope, or tree trunk protector
on the anchor.
• Always remove any element or obstacle that may interfere with
safe operation of the winch.
• Always take time to use appropriate rigging techniques for a
winch pull.
• Always be certain the anchor you select will withstand the load
and the strap or chain will not slip.
• Never engage or disengage clutch if winch is under load, rope
is in tension or drum is moving.
• Always select an anchor point as far away as possible. This will
provide the winch with its greatest pulling power.
• Never winch with less than 5 wraps of rope around the drum.
The rope could come loose from the drum.
• Never touch rope or hook while in tension or under load.
• Never touch rope or hook while someone else is at the control
switch or during winching operation.
• Always stand clear of rope and load and keep others away
while winching.
• Always be aware of stability of ATV/UTV and load during
winching, keep others away.
• Alert all bystanders of any unstable condition.
• Never use winch to secure a load.
• 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.
• Always prestretch wire rope and respool under load before use.
Tightly wound wire rope reduces chances of binding , which can
damage the rope.
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.
• Never use a hook whose throat opening has increased, or
whose tip is bent or twisted.
Falling or Crushing Hazard
Failure to observe these instructions could lead to severe injury or
death.
• Never use winch to lift or move persons.
• Never use winch as a hoist or to suspend a load.
Cut and Burn Hazard
Failure to observe these instructions could lead to minor or
moderate injury.
To avoid injury to hands and fingers:
• Always wear heavy leather gloves when handling a rope.
• Never let rope slip through your hands.
• Always be aware of possible hot surface at winch motor, drum
or rope during or after winch use.
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.
• Always avoid “powering out” for extended distances. This
causes excess heat and wear on the winch motor and brake.
• Always use care to not damage the ATV/UTV frame when
anchoring to a vehicle during a winching operation.
• Never “jog” rope under load. Shock loads can momentarily
exceed capacity of rope and winch.
• Never use winch to secure a load during transport.
• Never submerge winch in water.
• Always store the remote control in a protected, clean, dry area.
• Always double line or pick distant anchor point when rigging.
This maximizes pulling power and avoids overloading the winch.
To prevent accidental activation of the winch and serious injury,
complete the winch installation and attach the hook before
installing the wiring.
9
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.
• Lock washers.
• Hex head cap screws when using a one-piece winch mount plate.
Note: When using separate winch mount and fairlead plates use hex
head cap screws on the motor side of the base as shown in Figure 1.
• Torque the mounting bolts to 16 N-m (12 lb-ft)
• Attach the clevis hook to the wire rope:
»Put clutch in freespool position.
»Manually feed cable loop through fairlead.
»Attach hook to cable loop and re-engage clutch.
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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. It is
recommended that the control box be mounted close to the battery and
in a location that is as clean and dry as possible. Exact location will vary,
depending on the ATV. Usual locations include inside, on top, or on the
side of rear storage box, and on a few models, under the seat.
Ensure the control box mounting location selected provides sufficient
clearance from all metal structures such as frame tubes. Do NOT place
tools or other items in a position that might come in contact with the
control box directly. Drill the mounting holes for the control box at this
time, then move on to step four as it will be easier to attach all the wiring
to the control box before attaching it to the ATV. Do NOT mount the
control box at this time.
Figure 2: ATV/UTV Control Box
Ce manuel convient aux modèles suivants
2
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