Ramsey Winch HD-P8000 Installation and user guide

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE

INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!

OPERATING, SERVICE, AND

MAINTENANCE MANUAL

MODEL HD-P8000

PLANETARY WINCH

(PER JERR-DAN

SPECIFICATIONS)

TABLE OF CONTENTS

INTRODUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

HYDRAULIC SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

TYPICAL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

OVERHAUL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16

DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

PARTS LIST AND PARTS DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BACK COVER

PLEASE READ THIS MANUAL CAREFULLY

This manual contains useful ideas for obtaining the most efficient operation from your

Ramsey Winch, and safety procedures one needs to know before operating a Ramsey

Winch. Do not operate this winch until you have carefully read and understand the

"WARNING" and "OPERATION" sections of this manual.

WARRANTY INFORMATION

Ramsey Winches are designed and built to exacting specifications. Great care and skill

go into every winch we make. If the need should arise, warranty procedure is outlined

on the back of your self-addressed postage paid warranty card. Please read and fill out

the enclosed warranty card and send it to Ramsey Winch Company. If you have any

problems with your winch, please follow instructions for prompt service on all warranty

claims. Refer to back page for limited warranty.

SPECIFICATIONS*

NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufac-

turer for wire rope ratings.

Rated Line Pull (lbs.)

…………………………………………………

8,000

(Kg.)

…………………………………………………

3,620

Gear Reduction 5.1:1

………………………………………114 lbs. (51.8 Kg)

12345

lbs. 8,000 6,800 5,900 5,200 4,700

Kg. 3,620 3,080 2,670 2,350 2,120

ft. 15356085115

m 4 10 18 25 34

FPM5058677684

MPM 15.2 17.6 20.3 23.1 25.5

…………………………………………………………

Weight (without cable)

* These specifications are based on recommended wire rope of 3/8" (10mm)

galvanized aircraft cable, or EIPS cable and a 15.5 cu.in./Rev. motor.

LAYER OF CABLE

* Rated line pull

per layer

* Line Speed

(at 15 GPM)

Cable Capacity

WARNINGS:

A MOTOR SPOOL (OPEN CENTER) DIRECTIONAL CONTROL VALVE IS

REQUIRED FOR BRAKE OPERATION.

CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCH.

DO NOT DISENGAGE CLUTCH UNDER LOAD.

DO NOT LEAVE CLUTCH ENGAGED WHEN WINCH IS NOT IN USE.

STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS.

STAND CLEAR OF CABLE WHILE PULLING. DO NOT TRY TO GUIDE CABLE.

DO NOT EXCEED MAXIMUM LINE PULL RATINGS SHOWN IN TABLE.

DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PER-

SONNEL.

A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NEC-

ESSARY TO HOLD THE LOAD. CABLE CLAMP (SETSCREW) IS NOT

DESIGNED TO HOLD LOAD.

IN CAR CARRIER APPLICATIONS, AFTER PULLING VEHICLE ON CARRIER,

BE SURE TO SECURE VEHICLE TO CARRIER BED. DO NOT MAINTAIN LOAD

ON WINCH CABLE WHILE TRANSPORTING VEHICLE. DO NOT USE WINCH

AS A TIEDOWN.

WHEN PULLING A HEAVY LOAD PLACE A BLANKET, JACKET, OR TARPAULIN

OVER THE CABLE FIVE OR SIX FEET FROM THE HOOK.

AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR, AS THEY MAY

INDICATE A DANGEROUS SITUATION.

CONDITIONS POSSIBLE CAUSE CORRECTION/ACTION

DRUM WILL NOT

ROTATE AT NO LOAD

Winch not mounted squarely, causing

end bearing to bind up

Check mounting.

Gears damaged Inspect and replace damaged gears

DRUM WILL NOT

ROTATE UNDER LOAD

Winch not mounted squarely, causing

end bearing to bind up

Check mounting.

Load greater than rated capacity of winch Refer to Specifications page 3 for line pull

rating.

Low hydraulic system pressure Check pressure. Refer to Hydraulic Systems

performance charts page 7.

WINCH RUNS TOO

SLOW

Low hydraulic system flow rate Check flow rate. Refer to Systerm

Requirements and Typical Layout page 6.

Motor worn out Replace motor

DRUM WILL NOT

FREESPOOL

Clutch not disengaged. Check Adjustment

of Remote Shifter, page 14.

Check Clutch Operation, page 7.

Winch not mounted squarely, causing

end bearing to bind up

Check mounting.

Side mounted bolts too long, causing

binding of ring gear (Item #15, page 16).

Check bolt length. Bolt thread MUST NOT

engage threaded holes in sides of end bear-

ing more than the .50 inch thread depth in

the end bearing.

BRAKE WILL NOT

HOLD

Incorrect directional control valve (cylin-

der spool-closed center)

Use only a motor spool (open center) con-

trol valve.

LOAD DRIFTS Excessive Backpressure (100 PSI Max.) Check for restrictions in hydraulic system.

Refer to System Requirements and Typical

Layout page 6.

CABLE BIRD-NESTS

WHEN CLUTCH IS

DISENGAGED

Drag screw improperly adjusted Adjust nylon drag screw. Refer to Cable

Installation, page 8.

EXCESSIVE NOISE Hydraulic system flow too high Check flow rate. Refer to Typical Layout

page 6.

Drum in bind, winch not mounted

squarely

Check mounting.

DRUM CHATTERS IN

“REEL IN” DIRECTION

Low hydraulic system flow rate Check flow rate. Refer to Typical Layout

page 6.

Low hydraulic system relief pressure set-

ting

Check relief valve setting.

OIL LEAKS FROM

BREATHER VENT

UNDER MOTOR END

BEARING

Damaged brake o-rings, backup rings, or

sealing surfaces

Disassemble brake and inspect. See

Overhaul Instructions, pg. 11.

TROUBLESHOOTING GUIDE

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts on page 8 to properly match your hydraulic system to

the winch performance. The charts consist of:

(1) Line Pull first layer (lb.) vs. Working Pressure (PSI)

(2) Line Speed, first layer (FPM) vs. flow (GPM)

SYSTEM REQUIREMENTS

MOTOR SPOOL (OPEN CENTER) CONTROL VALVE REQUIRED

2500 PSI RELIEF VALVE SETTING

15 GPM FLOW RATE

DO NOT EXCEED 20 GPM--MOTOR AND WINCH MAY BE DAMAGED

10 MICRON NOMINAL FILTRATION

PORT CONTROL

(.75 I.D. MINIMUM)

LOW PRESSURE LINE

(.50 I.D. MINIMUM)

HIGH PRESSURE LINE

2500 PSI

15 GPM

RATED LOAD:

PRESSURE AT

MAX. FLOW &

(MOTOR SPOOL)

4 WAY VALVE

3 POSITION RELIEF

SYSTEM

PORT

BRAKE

MOTOR

WITH BRAKE RELEASE SHUTTLE

TYPICAL LAYOUT

WORKING PRESSURE (PSI) AT 15 GPM

GALLONS PER MINUTE (GPM)

LINE PULL-FIRST LAYER (LB)

LINE SPEED-FIRST LAYER (FPM)

0 5 10 15

1000

2000

3000

4000

5000

6000

7000

8000

1000 2000 2500

BASED ON 15.5 CU. IN. MOTOR

1500500

PERFORMANCE CHARTS

OPERATION

The best way to get acquainted with how your winch operates is to make test runs

before you actually use it. Plan your test in advance. Remember, you hear your winch as

well as see it operate. Get to recognize the sounds of a light steady pull, a heavy pull,

and sounds caused by load jerking or shifting. Avoid conditions where load shifts or

jerks occur, as they may indicate a dangerous situation.

The uneven spooling of cable, while pulling the load, is not a problem, unless there is a

cable pileup on one end of the drum. If this happens, reverse the winch to relieve the

load, and move your anchor point further to the center of the vehicle. After the job is

done you can unspool and rewind for a neat lay of the cable.

When pulling a heavy load, place a blanket, jacket, and tarpaulin over the cable about five

or six feet behind the hook. In the event of a broken cable, this will slow the snap back of

the cable and could prevent serious injury.

The winch clutch allows rapid unspooling of the cable, from the cable drum, for hooking

onto the load. The clutch is operated by the remote shifter.

WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD!

MANUAL REMOTE CLUTCH OPERATION

TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until the load

is off the cable. Lift up the knob and pull out, lock in place. See warning label located by

shifter knob. The clutch is now locked out and can be pulled off by hand.

TO ENGAGE CLUTCH: Lift up the knob then release. See warning label located by shifter

knob. Run winch in reverse until the shifter knob snaps fully in or until the cable starts

turning. At this poing make sure the shifter knob is all the way in. After the clutch is fully

engaged, the winch is ready for winching in the cable.

CABLE INSTALLATION

An “A” or “B” decal on the clutch end bearing indicates the spooling direction of

the cable. Also, a letter “A” or “B” is stamped in the end bearing on the clutch

end indicating rotation direction. If the decal is damaged or unreadable, contact

Customer Service for additional instructions to determine proper direction. To

reverse the rotation direction, exchange positions of the cartridge and

plug shown at right.

1. Unwind cable by rolling it out along the ground to prevent kinking. Securely

wrap end of cable, opposite hook, with plastic or similar tape to prevent

fraying.

2. Place taped end of cable into hole in cable drum as shown below. Use the

3/8-16NC x 1/2” long hex socket drive setscrew (included with drum

assembly item #1) to secure cable to drum.

3. Carefully run winch in the "reel-in" direction. Keeping tension on end of

cable, spool all the cable onto the cable drum, taking care to form neatly

wrapped layers.

After installing cable, check freespool operation. Disengage clutch and pull on

cable at a walking speed. If cable “birdnests”, loosen jam nut (item #20) and

turn nylon setscrew (item #17) clockwise to increase drag on drum. If cable pull

is excessive, loosen nylon setscrew by turning counterclockwise. Tighten jam

nut when proper setting is obtained. CAUTION: OVER-TIGHTENING OF JAM NUT

MAY STRIP NYLON SETSCREW.

MAINTENANCE

1. Inspect the cable for damage and lubricate frequently. If the cable becomes

frayed with broken strands, replace immediately.

2. Check that the clutch is fully engaging. See OPERATION instructions, above,

for the appropriate clutch shifter. FOR MANUAL CLUTCH ONLY: Monthly,

disengage clutch, put several drops of oil on the clutch handle shaft and

work clutch handle IN and OUT several times to lubricate inside the shifter

assembly.

3. Check to see that the drum cable does not overrun (“birdnest”) when

freespooling. Refer to page 3 if it does.

4. Replace drum bushings and seals if seals begin to seep grease. Refer to the

Overhaul Instructions, pages 7-12. Add additional lubricant, Mobilith SHC

007, to gears and drum bearings if required.

SETSCREW

"A" ROTATION

DIRECTION

"B" ROTATION

DIRECTION

INSERT CABLE AS SHOWN FOR "B" ROTATION

OVERWOUND APPLICATION.

(UNDERWOUND APPLICATION REQUIRES CABLE TO

COME UNDER DRUM FROM OPPOSITE DIRECTION

AND INSERTED IN THIS SAME CABLE POCKET.)

INSERT CABLE AS SHOWN FOR "A" ROTATION

OVERWOUND APPLICATION.

(UNDERWOUND APPLICATION REQUIRES CABLE TO

COME UNDER DRUM FROM OPPOSITE DIRECTION

AND INSERTED IN THIS SAME CABLE POCKET.)

PLUG

POSITION

CARTRIDGE

POSITION

CARTRIDGE

POSITION

CABLE DRUM

ROTATION DIRECTION

CABLE DRUM

ROTATION DIRECTION

"B" ROTATION

"A" ROTATION

(REEL IN) RAISE INLET

INSTRUCTIONS FOR OVERHAUL HD-P8000 WINCH

Take note of mounting configuration for proper mounting of parts during re-

assembly. Replace all gaskets, o-rings, and seals during re-assembly.

Remove frame assembly (item #2) by removing 8 capscrews (item #15).

Disconnect brake tube (item #42) from elbow fittings (item #24) on bottom of

end bearing housing and counterbalance valve (item #43). Remove motor from

end bearing by slowly unscrewing capscrews (item #18). CAUTION: MOTOR IS

UNDER SPRING PRESSURE.

Check breather vent (item #46). Make sure it is not clogged. If oil is leaking

from vent, check brake o-rings, backup rings, and sealing surfaces (see page

11).

Remove springs (item #41) from pockets and inspect for damage.

Remove gasket (item #25).

Remove motor coupling (#23) from end bearing. Examine coupling for signs of

wear, replace if necessary. If necessary, remove counterbalance valve (item

#43) from motor by removing capscrews (item #14)

42 43 21

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