Ramsey PROPLUS 6000, 8000T User Manual

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

Ramsey performance data is compiled from actual winch testing. Drum cable shown is not included with winch.

Noise Level 84 dB(A)

CURRENT

(Approx.)

(AMP)

LINE PULL

-0-

(lbs.)

3,000 3,370

1,000

-0-

(Kn)

13,34

4,44

OF CABLE

PERFORMANCE FIRST LAYER

(Approx.)

LINE SPEED

(FPM)

12V

5.5

6.1

13.7

(MPM)

12V

CABLE DRUM CAPACITY

BY LAYER

7,0mm dia. wire rope).

(based on recommended

LAYER

303

270

200

100

12V

3 4

Ft.

Intended purpose for Ramsey Pro Plus 6000T and Pro Plus 8000T Series Winches: Vehicle Recovery and Pulling of Loads.

Noise Level 79 dB(A)

4,000

2,000

-0-

4,940

17,79

8,89

-0-

22 11

3.4

5.5

10.7

CABLE DRUM CAPACITY

8,0mm dia. wire rope).

(based on recommended

BY LAYER

333

270

210

14 20

PERFORMANCE FIRST LAYER

OF CABLE

CURRENT

(Approx.)

(AMP)

12V

(MPM)

12V

LINE SPEED

(Approx.)

(FPM)

12V

LINE PULL

(lbs.) (Kn)

LAYER

Ft.

Safety Precautions To Guard Against Possible

Injury.....

A minimum of five wraps of cable around the drum barrel is necessary to hold the rated load. Cable clamp is not designed to hold the load.

A. Keep yourself and others a safe distance to the side of the cable when pulling under load.

B. Do not step over a cable, or near a cable under load. C. Use supplied hook strap when handling hook for

spooling wire rope. D. Do not move the vehicle to pull a load on the winch cable.

This could result in cable breakage and/or winch damage. E. Use a heavy rag or gloves to protect hands from burrs when

handling winch cable.

F. Apply blocks to wheels when vehicle is on an incline.

G. Winch clutch should be disengaged when winch is not in use and fully engaged when in use.

H. Modification, alteration, or deviation to the winch should only be made by Ramsey Winch Company.

I. 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 two minutes 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.

J. Disconnect the remote control switch from the winch when not in use. A safety on-off switch in your vehicle is required.

K. Do Not use winch in hoisting applications due to required hoist safety factors and features.

L. An overload device is required to prevent winch from exceeding maximum line pull ratings shown in tables.

M. To respool correctly, it is necessary to keep a slight load on the cable. This is accomplished by (wearing gloves) holding the cable with one hand and the remote control with the other, starting as far back and in the center as you can, walking up keeping load on the cable as the winch is powered in. Do not allow the cable to slip through your hand and do not approach the winch too closely. Turn off the winch and repeat the procedure until all the cable except a few feet is in.

Disconnect the remote control switch and finish spooling in cable by rotating the drum by hand with clutch disengaged. On hidden winches, spool cable in under power using supplied hook strap.

Tips for Safe Operation

Do not underestimate the potential danger in winching operations. Neither should you fear them. Do learn the basic dangers and avoid them.

The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pileup on one end of 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.

Store the remote control switch inside your vehicle where it will not become damaged. Inspect it before you plug it in.

When ready to begin spooling in, plug in remote control switch with clutch disengaged. Do not engage clutch with motor running.

Never connect the hook back to the cable. This causes cable damage. Always use a sling or chain of suitable strength as shown in the illustration, page 3.

Observe your winch while winching, if possible, while standing at a safe distance. If you use vehicle drive to assist, stop and get out every few feet to assure the cable is not piling up in one corner. Jamming cable can break your winch.

Do not attach tow hooks to winch mounting apparatus. They must attach to vehicle frame.

When double lining during stationary winching, the winch hook should be attached to the chassis of the vehicle.

Since the greatest pulling power is achieved on the innermost layer of your winch, it is desirable to pull off as much line as you can for heavy pulls. If this is not practical, use a snatch block and double line arrangement as shown in the illustration, page

3. Remember, a minimum of 5 wraps of cable around the drum barrel is necessary to hold the rated load.

Neat, tight spooling avoids cable binding. Cable binding occurs when a cable under load pulls down into the layer below, becoming pinched between two other wraps of cable. If this happens, alternately power the winch in and out a few inches. Do not attempt to work a bound cable under load; free by hand.

Techniques of Operation

The best way to get acquainted with how your winch operates is to make a few test runs before you actually need to use it. Plan your test in advance. Remember you hear your winch as well as see it operate. Get to recognize the sound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Soon you will gain confidence in operating your winch and its use will become second nature with you.

Your winch will not only pull you up or ease you down a steep grade, it will also pull another vehicle or a load while your vehicle is anchored in a stationary position. The following illustrations show a few basic winching techniques.

When pulling a heavy load, place a blanket, jacket or tarpaulin over the cable five or six feet from the hook. It will slow the snap back in the event of a broken cable. Also, open the vehicle hood for additional protection.

Use the vehicle wheel power to help the winch, but do not overtake the winch line. Plan your pull. You can not always hook up and pull out in one step. Examine the area for anchoring possibilities as well as leverage situations, direction, and goal.

For basic self recovery, anchor to a tree or heavy rock. When anchoring to a tree, always use a tree trunk protector.

Stakes driven in solid earth and chained together make a good anchor point for self-recovery when no solid anchor point is available.

For a solid anchor, bury a log with earth or sand or place it in a deep ravine

For a direct pull of 2,000 lbs., hitch truck to a tree or solid anchor, and take out of gear.

To double the pull, use 2-part line with snatch block and tie off to chassis. Take out of gear.

Winches equipped with cable guide fairleads can pull from several directions. Pull from an angle only to straighten up the vehicle-otherwise you can damage structural members or other parts of your vehicle and cause excess cable buildup on one end of the winch drum.

CONNECT BLACK GROUND CABLE TO NEGATIVE (-) TERMINAL OF VEHICLE BATTERY.

WINCH MOUNTING BOLT 3/8-16NC X 1-1/4 LG.

CLEVIS PIN

COTTER PIN

CABLE HOOK

HAWSE FAIRLEAD

FIGURE 1

CONNECT RED CABLE TO POSITIVE (+) TERMINAL OF VEHICLE BATTERY.

MOUNTING CHANNEL

FAIRLEAD MOUNTING BOLT 3/8-16NC X 1-1/4 LG.

CLUTCH SHIFTER KNOB

CONTROL SWITCH RECEPTACLE

Installation

It is very important that the winch be mounted on a flat surface so that the three major sections (the motor end, the cable drum, and the gear housing end) are properly aligned. It is recommended that Ramsey kits be used to mount the winch. They are designed to align the winch and distribute up to the full rated load evenly, to avoid possible damage to the winch or vehicle.

NOTE: If recommended mounting is not used, a kit of equal design must be used.

Also available for mounting the ProPlus 6000T and ProPlus 8000T are winch mounting channels, short length (23.63”) #408052 (black), medium length (30.00”) #408120 (black), and long length (36.00”) #408101 (black). It is recommended that Ramsey mounting channels be used in all non-Ramsey mounting.

Attach fairlead to channel using hardware furnished with winch. Attach winch to channel. Place (4) flatwashers and nuts into pockets of winch mounting feet and thread capscrews with lockwahers through mounting holes in channel and into hardware in winch feet (see FIGURE 1).

Substitution of attaching hardware items (bolts, nuts, or washers) different from those supplied with your winch and mounting kit can lead to failure causing damage or serious injury (use SAE grade 5 bolts or better and torque to 34 ft. lbs.).

Place end of wire rope through fairlead and attach cable hook. Use clevis pin and cotter pin (see FIGURE 1).

Operating Instructions

The winch clutch allows rapid unspooling of the cable for hooking onto the load or anchor point. The clutch is operated by the shifter knob located on the gear housing end of the winch as follows:

1. To disengage the clutch, move the clutch shifter knob to the "OUT" position. Wire rope may now be freespooled off the drum.

2. To engage the clutch, move the clutch shifter knob to the "IN" position. The winch is now ready for pulling.

Electrical Connections and Operations

For normal self-recovery work, your existing electrical system is adequate. 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.

Route battery cables up to battery. CAUTION: BE SURE BAT-

TERY CABLES ARE NOT DRAWN TAUT ACROSS ANY SURFACES WHICH COULD POSSIBLY DAMAGE THEM. Connect

red cable to positive (+) battery terminal. Connect black ground cable to negative (-) terminal of battery and to winch mounting bolt on motor end of winch (see FIGURE 1).

An emergency stop switch (reference Ramsey part no.

282053) is required between the positive (+) battery terminal and the red winch cable. An overload device is required to prevent winch from exceeding the rated line pull.

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 lead to solenoid failure. Make sure the motor has stopped fully before reversing. To actuate winch, simply plug remote control switch into receptacle in cover of winch. Run winch forward and reverse to check connection and to 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 at the direction your winch will run. Pushing both buttons at the same time will not damage your winch in any way. DO NOT LEAVE SWITCH PLUGGED IN WHEN WINCH IS NOT IN USE.

Corrosion on electrical connections will reduce the performance or may cause a short. Clean all connections, especially in remote control switch and receptacle. In salty environments use a silicone sealer to protect from corrosion.

Lubrication/Cable Installation

All moving parts in the winch are permanently lubricated with high temperature lithium grease at the time of assembly. Under normal conditions, factory lubrication will suffice.

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

Unwind the new cable by rolling it out along the ground to prevent kinking. Remove old cable and observe the manner in which it is attached to the cable drum flange.

Before installing the new cable assembly, securely wrap the end of the cable with plastic tape or similar tape to prevent fraying.

Position the cable drum so that the large 13/32” diameter hole in the motor end drum flange is approximately on the top. Form a short bend (approximately 1/2” long) in the end of the cable. Insert the bend into the 13/32” hole in the drum flange and then carefully run the winch in the “reel in” direction approximately 3/4 revolution until the 1/4” diameter threaded hole in the drum flange is on top. Secure the cable to the drum flange using cable anchor and capscrew shown in the parts drawing on page 7. Securely tighten the capscrew, but do not over-tighten.

Wind 5 wraps of cable onto the drum. Wind on the rest of the cable by pulling in a light load to keep the tension constant. Allow the cable to swivel by using a length of chain or a swivel block between the cable hook and the load.

CONDITIONS POSSIBLE CAUSE CORRECTION

MOTOR RUNS IN ONLY ONE Defective solenoid or stuck solenoid. Jar each solenoid to free contacts. Check each solenoid by

DIRECTION applying power to coil terminal (it should make an audible

click when energized).

Defective remote control switch Disengage winch clutch, remove remote control switch

plug. 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.

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------MOTOR RUNS EXTREMELY HOT Long period of operation Cooling-off periods are essential to prevent overheating.

Insufficient battery Check battery terminal voltage under load. If 10 volts or

less, replace or parallel another battery to it.

MOTOR RUNS, BUT WITH Bad connection Check battery cable for corrosion; clean and grease. INSUFFICIENT POWER, OR WITH LOW LINE SPEED Insufficient charging system Replace with larger capacity charging system.

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------MOTOR RUNS, BUT DRUM Clutch not engaged If clutch engaged but symtoms still exists, it will be DOES NOT TURN necessary to disassemble winch to determine cause and repair.

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------MOTOR WILL NOT OPERATE Defective solenoid or stuck solenoid. Jar solenoid to free contacts. Check solenoid by applying

power to coil terminal (it should make an audible click when energized).

Defective remote control switch plug Disengage winch clutch, remove rem ote 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.

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

replace motor.

Loose connections Tighten connections on bottom side of hood and on motor.

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------MOTOR WATER DAMAGED Submerged in water or water Allow to drain and dry thoroughly, then run motor without

from high pressure car wash a load in short bursts to dry windings.

Trouble Shooting Guide