OPERATING, SERVICE AND MAINTENANCE MANUAL

MODEL HD-P8000 PLANETARY WINCH

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!

TABLE OF CONTENTS

INTRODUCTIONS ........................................................................................... 1

WARRANTY INFORMATION ........................................................................... 1

SPECIFICATIONS ........................................................................................... 1

WARNINGS....................................................................................................... 1

CABLE INSTALLATION ................................................................................... 2

HYDRAULIC SYSTEM REQUIREMENTS ....................................................... 3

TYPICAL LAYOUT ........................................................................................... 3

PERFORMANCE CHARTS .............................................................................. 3

OPERATION .................................................................................................... 4

MAINTENANCE ............................................................................................... 4

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

OVERHAUL INSTRUCTIONS .......................................................................... 6-11

DIMENSIONAL DRAWINGS ............................................................................ 12-13

PARTS LIST AND PARTS DRAWINGS ........................................................... 14-17

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

1

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

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 PERSONNEL.

• A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY 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.

Rated Line Pull (lbs.) …………………………………………………… 8,000

(Kg.) …………………………………………………… 3,620

Gear Reduction 5.1:1

HD-P8000 STD. ……..…....………. 82 lbs. (37.2 Kg)

HD-P8000 "Y" ………….………….. 76 lbs. (34.5 Kg)

1 2 3 4 5

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

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

ft. 25 55 90 130 170

m 7 16 27 39 51

ft. 15 35 60 85 115

m 4 10 18 25 34

FPM 50 58 67 76 84

MPM 15.2 17.6 20.3 23.1 25.5

……………………………………………………………

Weight (without cable)

LAYER OF CABLE

*Rated line pull per layer

HD-P8000 (STD. DRUM)

* Line Speed (at 15 GPM)

HD-P8000 ("Y" DRUM)

* Cable Capacity per Layer

PLEASE READ THIS MANUAL CAREFULLY This manual contains useful ideas for obtaining the most efficient operation from your Ramsey Winch, and safety pro-cedures 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*

2

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 direc-tion, exchange positions of the cartridge and plug shown below. 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. Insert the end of the cable through roller fairlead.

3. Place taped end of cable under tensioner plate and into hole in cable drum. Use the 3/8-16NC x 1/2” long hex socket drive setscrew (included with drum assembly) to secure cable to drum.

4. Carefully run winch in the "reel-in" direction. Wind about 5 wraps of cable onto the drum and stop. Using a ham-mer tap these five wraps tightly over against the cable anchor flange of the drum. 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.

(REEL IN) RAISE INLET

"A" ROTATION "B" ROTATION

CABLE DRUMROTATION DIRECTION

CABLE DRUMROTATION DIRECTION

CARTRIDGEPOSITION CARTRIDGE

POSITION

PLUGPOSITION

17

20

INSERT CABLE AS SHOWN FOR "A" ROTATIONOVERWOUND APPLICATION.

(UNDERWOUND APPLICATION REQUIRES CABLE TOCOME UNDER DRUM FROM OPPOSITE DIRECTION

AND INSERTED IN THIS SAME CABLE POCKET.)

INSERT CABLE AS SHOWN FOR "B" ROTATIONOVERWOUND APPLICATION.(UNDERWOUND APPLICATION REQUIRES CABLE TOCOME UNDER DRUM FROM OPPOSITE DIRECTIONAND INSERTED IN THIS SAME CABLE POCKET.)

"B" ROTATIONDIRECTION

"A" ROTATIONDIRECTION

SETSCREW

NOTE: VIEW SHOWN WITHOUTCABLE TENSIONER FOR CLARITY.

CABLE IN DIRECTION CABLE IN DIRECTION

3

HYDRAULIC SYSTEM REQUIREMENTS Refer to the performance charts below 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

PUMP

(.75 I.D. MINIMUM)LOW PRESSURE LINE(.50 I.D. MINIMUM)

HIGH PRESSURE LINE

2500 PSI15 GPMRATED LOAD:PRESSURE ATMAX. FLOW &

(MOTOR SPOOL)4 WAY VALVE3 POSITION

RELIEFSYSTEM

A

PORTBRAKE

MOTOR

WITH BRAKE RELEASE SHUTTLE TYPICAL LAYOUT

B

WORKING PRESSURE (PSI) AT 15 GPMGALLONS PER MINUTE (GPM)

LIN

E P

ULL

-FIR

ST

LAY

ER

(LB

)

LIN

E S

PEED

-FIR

ST L

AYER

(FPM

)

0 5 10 1510

20

30

40

00

1000

2000

3000

4000

5000

6000

7000

8000

1000 2000 2500

50

BASED ON 15.5 CU. IN. MOTOR

1500500

PERFORMANCE CHARTS

4

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 oper-ate. 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 dan-gerous 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 clutch shifter lever or air shifter.

WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD! MANUAL CLUTCH SHIFTER (Refer to dimensional drawing page 12): TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until the load is off the cable. Pull handle out and rotate 90°. With handle in the DISENGAGED” position, cable may now be free-spooled from the drum. TO ENGAGE CLUTCH: Pull handle out, rotate 90° and re-lease handle. Run the winch in reverse until the clutch handle snaps fully into the “ENGAGED” position. DO NOT attempt to pull a load unless the handle is fully at the “ENGAGED” position. AIR CYLINDER CLUTCH SHIFTER (Refer to the dimensional drawing page 13): TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the cable. Apply air pressure to the .125-27 NPT port: 80 PSI (min.)-150 PSI (max.). CAUTION: PRESSURE MUST NOT EXCEED 150 PSI. TO ENGAGE CLUTCH: Remove air pressure from the cylinder (a return spring engages the plunger). Run winch in reverse until the clutch engage-ment indicator light (green light) is lit. To install light to the vehicle electrical system refer to the Electrical Schematic on page 13. MAINTENANCE 1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with bro-

ken strands, replace immediately. Cable and hook assembly (100’ long cable) P/N 524118 may be purchased from a Ramsey distributor.

2. Check that the clutch is fully engaging. See OPERATION instructions, above, for the appro-priate 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 2 if it does.

4. Replace drum bushings and seals if seals begin to seep grease. Refer to the Overhaul In-structions, pages 6-11. Add additional lubricant, Mobilith SHC 007, to gears and drum bear-ings if required.

5

TROUBLESHOOTING GUIDE

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 1 for line pull rating.

Low hydraulic system pressure Check pressure. Refer to Hydraulic Systems per-formance charts, page 3.

WINCH RUNS TOO SLOW Low hydraulic system flow rate Check flow rate. Refer to System Requirements and Typical Layout, page 3.

Motor worn out Replace motor

DRUM WILL NOT FREESPOOL Clutch not disengaged. Check Adjustment of Manual Shifter, page 10.

Check Operation, page 4.

Winch not mounted squarely, causing end bearing to bind up

Check mounting.

Side mounted bolts too long, causing binding of ring gear (Item #32, page 14).

Check bolt length. Bolt thread MUST NOT engage threaded holes in sides of end bearing more than the .50 inch thread depth in the end bearing.

BRAKE WILL NOT HOLD Incorrect directional control valve (cylinder spool-closed center)

Use only a motor spool (open center) control valve.

LOAD DRIFTS Excessive Backpressure (100 PSI Max.) Check for restrictions in hydraulic system. Refer to System Requirements and Typical Layout, page 3.

CABLE BIRDNESTS WHEN CLUTCH IS DISENGAGED

Drag screw improperly adjusted Adjust nylon drag screw. Refer to Cable Installation, page 2.

EXCESSIVE NOISE Hydraulic system flow too high Check flow rate. Refer to Typical Layout page 3.

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 3.

Low hydraulic system relief pressure setting 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. 7.

6

INSTRUCTIONS FOR OVERHAUL HD-P8000 SERIES WINCH Take note of mounting configurations for proper mounting of parts during re-assembly. Replace all gaskets, o-rings, and seals during re-assembly. Disconnect tube (item #49) from elbow fittings (items #30) on bottom of end bearing and counterbalance valve (item #50). Remove motor (item #34) from end bearing by slowly unscrewing capscrews (items #22). CAUTION: MOTOR IS UNDER SPRING PRESSURE. Check breather vent (item #33). Make sure it is not clogged. If oil is leaking from vent, check brake o-rings, backup rings, and sealing surfaces (see page 7). Remove springs (items #48) from pockets and inspect for damage. Replace gasket (item #31). Remove coupling (item #29) from end bearing. Examine coupling for signs of wear, re-place if necessary. If necessary, remove counterbalance valve from motor by removing capscrews (items #16).

22

28

34

31

29

16

265049

3048

7

Remove retaining rings (items #46 and #47) with screwdriver. Remove brake parts from end bearing. NOTE POSITION OF O-RINGS AND BACKUP RINGS BEFORE REMOVAL. Examine brake discs (items #7) and stators (items #6) for signs of wear, and replace if necessary. Examine o-rings (items #35 and 36) and backup rings (items #38 and 40) in brake piston (item #8), as well as o-ring (item #37) and backup ring (item #39) in backup brake piston (item #9) for signs of wear. Remove o-rings and backup rings from grooves in brake piston or backup brake piston and replace if necessary.

46

8

3836

4035

9

3739

6

7

47

8

Remove nuts (item #66), washers (item #28), springs (item #60), and capscrews (item #55) from spring tensioner. Spring tensioner may be left partially assembled when removing capscrews (item #65). Refer to exploded views on pages 14 and 16 for all components. CAUTION: Both tensioner assembly and mounting angle (item #3) will come off at the same time when mounting angle capscrews (item #65) are removed. Slide motor end bearing (item #11) and drum (item #1) from gear housing end bear-ing. Remove input shaft (item #13) from end bearing. Inspect shaft and output sun gear (item #10) for dam-age and replace if necessary. To remove the output sun gear, remove the snap rings (items #45) and thrust washer (item #52) and pull off the end of the shaft. Remove bushing (item #15) and o-ring (item #41) from motor end bearing. Place new, well-oiled o-ring into groove inside of end bearing and press new bushing onto end bearing.

Remove seal (item #44) from gear housing end bearing (item #12). Loosen nut (item #24) and remove nylon set-screw (item #21). Remove ring gear from gear housing end bearing, if necessary. Remove bushing (item #14) from end bearing. Press new bushing into end bearing. Install ring gear, then nylon setscrew and nut. Ring gear must be fully seated in end bearing and slot in ring gear MUST NOT be aligned with clutch shifter hole. Install new seal in end bear-ing, with sharp edge of seal outward.

2124

44

32

1214

1

19

2

65

3

13

1052

45

11

41

15

60

28

66

55

9

Generously apply grease (MOBILITH SHC 007) to teeth of ring gear (item #32), teeth of planet gears in drum (item #1), and to bushing (item #14) in gear housing end bearing. Apply a small amount of grease to base of bushing (item #15) on motor end bearing. Apply grease to teeth of output sun gear (item #10) and input shaft (item #13).

Place end of shaft with output sun gear on it into drum (item #1). Rotate shaft to engage planet gears with output sun gear. Place Gear End Bearing on Drum and engage planet gears with ring gear.

Assemble motor end bearing (item #11) to drum assembly and use mounting angle (item #2) and capscrews (items #19) loosely to hold both end bearings together. Assemble mounting angle (item #3) and partial ten-sioner assembly together with capscrews (item #65). CAUTION: Mounting angle capscrews are different lengths! Ensure the correct capscrews are installed. Tighten capscrews to 55 ft-lbs (75 Nm). If neces-sary, remove and replace the shifter assembly (manual, item #5, or air-cylinder, item #6), as follows:

MANUAL CLUTCH SHIFTER ASSEMBLY Loosen setscrew (item #23) and jam nut, then unscrew shifter assembly (item #5). Be sure slot in ring gear is not aligned with clutch shifter hole. Rotate drum, if necessary, to ensure hole and slot are not aligned. Reinstall shifter assembly with plunger, jam nut, and handle positioned in gear housing as shown below. Thread assembly (with handle engaged in cylinder slot) into the gear housing. Pull drum toward the gear end bearing housing to remove play. Hold drum in position and continue threading the shifter assembly in until the gap between the end of the handle and cylinder is 7/16 +0/ -1/16 inch and handle is in the horizontal position (see below). Note: This gap will vary with drum endplay. With the drum pulled against the motor end housing, the gap should be 3/8 inch.

Lightly tighten jam nut. Rotate drum until handle snaps fully into the engaged position. Pull handle out and rotate 90°. Verify that drum can be rotated freely (at least one full revolution) with clutch shifter at the DIS-ENGAGED position. Securely tighten jam nut while holding the handle. Tighten setscrew (item #23) se-curely. Re-check clutch operation as described on page 4.

AIR CYLINDER SHIFTER ASSEMBLY Loosen set screw (item #23) to remove shifter assembly (item #6). To reinstall, place 1 or 2 shims (items #48) over plunger and thread shifter assembly into gear end housing. Add or remove shims to orient ports for pneumatic connections. Ports should point down (below horizontal). Tighten setscrew. Check for clutch operation as described on page 4.

51

43

12

23

5

20

48

6

CYLINDER

HANDLE (HORIZONTAL)

MANUAL CLUTCH ADJUSTMENT

MANUAL CLUTCH SHIFTER

AIR-CYLINDER CLUTCH SHIFTER

PLUNGER

JAM NUT

10

Set winch with gear housing end down on work surface. Install well-oiled o-rings and backup rings into grooves on outside of brake piston and backup brake pis-ton as shown in cross-section A-A below. Piston, backup piston, brake discs and stators must be clean and free of grease and oil. Insert brake discs (item #7) and stators (item #6) into gear end alternating, with stators first and last. Insert backup brake piston (item #9) into motor end and insert brake piston (item #8) into it. Apply even pressure on piston when installing. Install retaining rings (item #46 and #47) into grooves in motor end housing.

7

6

39

37

9

3540

36

38

8

46

A

A

SECTION A-A8 9

38 36 37 39

35

40

MOTOR SIDE

DRUM SIDE

47

11

Insert springs (item #48) into pockets in back of brake piston. The two empty pockets should be on op-posite sides.

Install roll pin (item #42) into new motor coupling below bottom of spline teeth. Insert motor cou-pling (item #29), engaging it with the discs and the input shaft.

Place gasket (item #31) on mounting surface of motor (item #34). Slide motor shaft into coupling. Attach motor to motor end bearing housing using (2) capscrews (item #22) and (2) lockwashers (item #28). Evenly tighten to 49 ft-lbs. (66 Nm) torque.

Install the counterbalance valve (item #50) to the motor using (4) capscrews (item #16) and (4) lock-washers (item #26). Tighten to 17 ft-lbs (23 Nm).

Securely connect fittings (item #30) to motor end housing and counterbalance valve, and connect tube assembly (item #49) to fittings.

Apply at least 550 PSI hydraulic system pressure to brake and verify that brake releases (winch drum will rotate).

Insert capscrews (item #55) through top plate and slotted tensioner plate. Install springs (item #60), washers (item #28), and secure with nylon lock nuts (item #66) to desired cable tension. Springs require a small amount of compres-sion before capscrews engage nylon lock nut threads. If it is difficult to compress springs to engage capscrews with nylon lock nut, loosen tensioner mounting bolts (item #65). Tighten capscrews to 55 in-lb (75 Nm). Recommended spring com-pression is 0.75” per spring. See figure at right.

Insert the end of the cable into the opening of the roller fair-lead so that it passes under the tensioner plate and install cable into the cable anchor.

Watch the tensioner as the cable is spooled onto the drum. The tensioner must be free to move without obstruction to function properly. If tensioner touches any surrounding structure, correct the problem.

Refer to Cable Installation, page 2 for information on install-ing the cable.

55

66

28

60

3

65

42

33

22

28

34

31

29

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16

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18 914184-0309-B

LIMITED WARRANTY

RAMSEY WINCH warrants each new RAMSEY Winch to be free from defects in material and workmanship for a period of one (1) year from date of purchase. The obligation under this warranty, statutory or otherwise, is limited to the replacement or re-pair at the Manufacturer's factory, or at a point designated by the Manufacturer, of such part that 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 to bear the cost of labor or transportation charges in connection with the replacement or repair of defective parts, nor shall it apply to a product upon which repair or alterations have been made, unless authorized by Manufacturer, or for equipment misused, neglected or which has not been installed correctly. RAMSEY WINCH shall in no event be liable for special or consequential damages. RAMSEY WINCH makes no warranty in respect to accessories such as being subject to the warranties of their respective manufacturers. RAMSEY WINCH, whose policy is one of continuous improvement, reserves the right to im-prove its products through changes in design or materials as it may deem desirable without be-ing obligated to incorporate such changes in products of prior manufacture. If field service at the request of the Buyer is rendered and the fault is found not to be with RAMSEY WINCH's product, the Buyer shall pay the time and expense to the field representa-tive. Bills for service, labor or other expenses that have been incurred by the Buyer without ap-proval or authorization by RAMSEY WINCH will not be accepted See warranty card for details.

RAMSEY WINCH COMPANY PO BOX 581510

Tulsa OK 74158-1510 Telephone: (918) 438-2760

FAX: (918) 438-6688 Visit us at www.ramsey.com