RAMSEY HYDRAULIC PLANETARY WINCH MODEL WILDCAT 80K
PLEASE READ THIS MANUAL CAREFULLY
This manual contains useful ideas in 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 "WARNINGS" 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*
APPROXIMATE WEIGHT: 1700 LBS
WORKING PRESSURE: 2500 PSI
CABLE DIAMETER: 1 INCH
MAX FLOW: 60 GPM
LAYER
OF
CABLE
1 50 20 80000 36280
2 115 45 66600 30200
3 185 73 57100 25900
4 270 106 50000 22670
5 365 144 44400 20130
* These specifications are based on recommended wire rope of 1” Extra Improved Plow Steel Cable and a 9.0
cu. in. / Rev. motor.
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.
CABLE
CAPACITY
Ft m Lb Kg
LINE PULL
LOW SPEED
LINE SPEED
fpm mpm
HIGH SPEED
LINE PULL LINE SPEED
Kg fpm mpm
30000
25000
21400
18700
16600
13630 60 18
11350 72 22
9730 84 26
8520 96 29
7560 108 33
WARNINGS:
CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.
DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
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 PEOPLE.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.
CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD.
BAND BRAKE IS NOT TO BE USED TO HOLD LOAD
1 OM-914207-0211-D
HYDRAULIC SYSTEM REQUIREMENTS
Refer to the performance charts, below, to properly match your hydraulic system to winch performance.
The charts consist of:
(1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) line speed, first layer (FPM) vs. gallons per
minute (GPM). Performance based on a motor displacement of 9.0 cubic inches/rev with 60 GPM
maximum flow rate. Motor has (2) 1”-12 SAE straight thread o-ring ports.
Note: A motor spool (open center) directional control valve is required for brake operation.
LOW PRESSURE LINE
DIRECT LINE TO TANK
BRAKE
MOTOR CASE DRAIN
MOTOR 2 SPEED
PERFORMANCE CHARTS
SAE -16
1" TUBING SIZE
12 VDC
PORT #5
SHIFT SOLENOID
COUNTER BALANCE
VALVE
COUNTER BALANCE/SPEED SELECTOR BLOCK
PORT#3
PORT #1
SAE -16
1" TUBING SIZE
HIGH PRESSURE LINE
PAYOUT
PAYIN
CLUTCH
80K AIR CONNECTIONS
BAND BRAKE
3 POSITION
4 WAY VALVE
SYSTEM
RELIEF
PUMP
CUSTOMER
SUPPLIED
BASED ON 9.0 CU IN/REV MOTOR
2 OM-914207-0211-D
CABLE INSTALLATION
1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of wire
rope, opposite hook, with plastic or similar tape to prevent fraying.
2. Place taped end of cable into slot on drum flange and bend into track on drum flange. Secure
using supplied u-bolt #62 and (2) nuts.
3. Carefully run the winc h in the “reel-in” direction. Keeping tensio n on end of cable, spool all the
cable onto the cable drum, taking care to form neatly wrapped layers.
4. After installing cable, band brake is used to prevent bird nesting while pulling out cable, when
clutch is disengaged.
62
BEND INTO TRACK
AS SHOWN
62
INSERT END OF CABLE
INTO SLOT AS SHOWN
3 OM-914207-0211-D
CLUTCH OPERATION
WARNING: CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.
To engage clutch:
1. Move clutch control to engage the clutch.
2. Run the motor in the cable out direction until the drum begins to turn.
WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD.
To disengage clutch:
1. Run the winch in the "cable out" direction until the load is off the cable.
2. Move the clutch control to disengage the clutch. The cable may now be spooled off.
WINCH OPERATION
The best way to get acquainted with how your winch operates is to make test runs before you use
it. Plan your test in advance. Remember, you hear your winch, as well as see it operate; learn to
recognize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or
shifting. Gain confidence in operating your winch and its use will become second nature with you.
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.
MAINTENANCE
Adhering to the following maintenance schedule will keep your winch in top condition and performing
as it should with a minimum of repair.
A. WEEKLY
1. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and
repair.
2. Check the pressure relief plug on the gear housing cover and the brake housing cover. Be sure they
are not plugged.
3.
Lubricate cable with light oil.
4. Lubricate drum bushings with grease.It is necessary to remove cable to expose the grease zerks on
drum. Use high quality lithium grease for best results.
5. Apply a high quality lithium grease to clutch spline. Apply band brake to control drum. Declutch drum
and apply grease to spline between clutch and drum.
B. MONTHLY
1.
Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are
loose. Use grade 5 or better bolts.
2. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.
C. ANNUALLY
Drain the oil from the winch annually or more often if winch is used frequently.
1.
2. Refill the winch to the oil level plug with all purpose GL-5 oil, (see page 5) for gear lube compatible with
1. Clutch not disengaged 1. Check operation. Refer to Clutch
1. Incorrect directional control valve.
(cylinder spool, closed center).
2. Excessive hydraulic system back
pressure.
3. Sprag clutch worn out.
1. Brake line disconnected or blocked 1. Repair brake line.
1. Replace seal
2. Drain excess oil. Refer to page 6.
3. Replace o-rings.
4. Connect case drain.
1. Check flow rate. Refer to HYDRAULIC
SYSTEMS performance chart on page 2.
2. Replace motor.
Operation on page 4.
1. Use only a motor spool (open center)
directional control valve.
2. Reduce system back pressure to less
than 100 psi.
3. Replace sprag clutch mechanism.
WINCH WILL NOT
OPERATE AT HIGH SPEED
WINCH OPERATES
ERRATICALLY ON INHAUL
1. Shift solenoid not working. 1. Verify shift spool is energized.
1. Sprag hub is reversed. 1. Install sprag hub correctly.
5 OM-914207-0211-D
INSTRUCTIONS FOR DISASSEMBLY
1. Remove wire rope from drum.
2. Drain oil from winch by removing (2) plugs #54, removing the lower plug first.
3. When replacing lubricant, use 264 oz of applicable lube for your climate form table on page 5,
adding 4 oz at #44 and the remaining at # 55.
4. Remove (2) nuts #208b from air cylinder #208a. Air cylinder may now be removed. If needed,
mounting bracket #201 may be removed by removing pin #204 from pin #205 and then sliding
pin out of mounting bracket. Brake band #5 may be expanded over drum flange to barrel for
easiest removal.
44
55
54
54
14
38
5
NOTE:
BRAKE BAND FITS
OVER DRUM FLANGE
208b
201
204
205
208a
6 OM-914207-0211-D
5. Remove motor #45 from winch by first disconnecting hydraulic lines (see page 17), solenoid
wires, and then remove (4) bolts #73. O-ring #72 may now be removed.
6. Remove brake cover #42 by removing (4) bolts #66. The cover is spring loaded, use care when removing. Remove o-ring #46 then springs #61 may be removed; residual oil may be
present in the brake housing.
7. Remove piston #11 including o-rings and backup rings #47, #48, #49, and #50 by using a
momentary puff of compressed air into the brake port located on top of the end bearing.
Capture the piston by placing a shop rag over the opening prior to using air.
8. Remove the sprag brake hub assembly #40, (7) stator plates #12, (6) disc brakes #13, and the
spacer #28. The sprag brake hub assembly #40 is not a serviceable part, if damaged a
replacement assembly should be ordered.
11. The planetary carrier assembly #4 may now be removed along with (2) spacers #24.
12. Remove second snap ring #58 and intermediate sun gear #16.
13. Planetary carrier assembly #3 may now be removed.
3
24
4
24
51
10
36
17
58
16
58
8 OM-914207-0211-D
14. Using a nylon strap, support ring gear #20 from a hoist or boom, this ring gear is heavy.
Remove (8) bolts #37 leaving the top most bolt for last. Remove the final bolt while supporting
ring gear. Set ring gear aside. Remove the o-ring #52.
15. Remove spacer #26 and the output sun gear #15.
16. Using a large pair of snap ring pliers remove the snap ring #60 from the shaft located inside
the planetary carrier assembly #2.
17. Using a nylon strap and hoist slide the output planetary carrier #2 from the ring gear housing.
The output planetary carrier is heavy.
18. Remove the spacer #27.
2
60
15
52
20
37
26
27
9 OM-914207-0211-D
19. Remove the clutch cylinder #1 by removing the (2) cotter keys #204 and (2) pins #206 from
either end of the air cylinder #207.
20. The clutch cylinder support angle #8 can be removed by removing the four bolts #66 and nuts
#65 attaching it to the mounting angles.
21. Remove the clutch yoke #29 by removing center pivot bolt #21 and nut #65.
NOTE:
VIEW SHOWN LESS DRUM AND ANGLE CUT AWAY FOR CLARITY
21
65
66
29*
1
* CLUTCH YOKE #29 SHOWN REMOVED
AND PARTIALLY INSTALLED
FOR CLARITY
206
204
204
207
29*
206
209
65
66
202
8
10 OM-914207-0211-D
22. By removing snap ring #58 and ball bearing #31, the input shaft #22 may be removed.
23. To remove the motor end bearing #18, support drum #14 with a nylon strap or chain and hoist.
Lift on the drum to tension the strap. Remove (6) bolts #67 and (6) nuts #68 attaching the end
bearing to the mounting angles #6 and #7. The motor end bearing #18 will be supported on the
output shaft end and may be slid off using a nylon strap and hoist to lift it.
14
67
18
22
68
31
58
7
6
67
11 OM-914207-0211-D
24. While continuing to support the drum #14, remove the clutch #9, snap ring #60 and spacer
#25.
25. The output shaft #23 may be slid from the drum assembly.
26. The drum #14 is now supported only by the nylon strap and maybe removed as needed.
27. The (2) bushings #34 may be pressed from the drum if replacement is necessary.
14
34
23
25
60
9
34
12 OM-914207-0211-D
28. To remove gear end bearing #18, from mounting angles #6 and #7, first remove (4) 7/8-9NC
bolts #67 and (4) nuts #68from each angle. Shaft oil seal #56 and end bearing bushing # 33
can be removed and replaced at this time, if necessary.
67
7
33
56
6
18
68
67
68
13 OM-914207-0211-D
DISASSEMBLY OF CARRIER ASSEMBLY
Carrier assemblies may be purchased as a complete assembly (see pg. 19) or parts may be
purchased individually (see pg 16). If purchasing individual parts, it will be necessary to
disassemble the gear carrier as outlined below. Disassembly/ assembly of carriers utilizes the
same process for input carrier assembly #4, intermediate carrier assembly #3, and output
carrier assembly #2. Detail shown below is for intermediate carrier assembly#3. Please see
page 16 for detailed parts list and drawings of individual carriers.
1. Carefully drive roll pin #112 into carrier pin #111 so that it is captured within carrier pin #111
but not touching the opposite side of the intermediate carrier #102.
2. Tap carrier pin #111 to remove it from the intermediate carrier #102.
3. Place a plastic pail in a position to catch bearings #110, spacer #108 and washers #115, then
slide the gear #105 from the carrier assembly #102.
4. Remove the roll pin #112 from the carrier pin #111.
5. Repeat this process for the two remaining gears in the carrier.
112
115
105
110
108
110
115
102
INTERMEDIATE CARRIER
111
14 OM-914207-0211-D
ASSEMBLY OF CARRIER ASSEMBLY
1. Place carrier #102 on flat clean surface.
2. A tool the width of the gear #105 and the diameter of the carrier pin #111 is helpful to install
needle bearings #110.
3. Place the gear #105 on a flat thin clean metal plate; metal plate should not be thicker than
thrust washer #115 and should be able to slide into gear pocket of carrier. Grease the inside of
gear and insert the greased tool described above into gear.
4. Place one row of needle bearings #110 into gear #102 carefully sliding them down the gap
between the tool and the gear so they stand vertically.
5. If more than one row of needle bearings is required, as shown in intermediate carrier, install
spacer #108, and the next row of needle bearings #110 as detailed in step 4 above until all
bearings are installed.
6. With tool remaining in place slide the gear #105 (resting on the thin plate) into position in the
carrier #102.
7. Place thrust washer #115 on top of gear #105. Insert planet pin #111 into carrier #105
8. Turn carrier #102 on its side so that the gear is on top. Remove the thin plate. Remove tool by
pushing planet pin #111 into carrier #102 until planet pin is at least half way past the last row of
bearings #110. The tool may now be removed completely.
9. Insert a thrust washer between gear #105 and carrier #102. Completely insert planet pin #111
into carrier #102 using care to align the roll pin hole in planet pin #111 with the roll pin hole in
the carrier #102.
10. Drive roll pin #112 into carrier #102 until roll pin #112 is flush with surface of the carrier #102.
11. Repeat this process to install the two remaining gears into the carrier.
15 OM-914207-0211-D
CARRIER ASSEMBLIES
115
Input Carrier*
112
106
109
115
113
101
* Input Gear Assembly may be purchased under part n umber 296672
* Intermediate Gear Assembly may be purchased under part number 296671
INTERMEDIATE CARRIER*
110
108
110
111
115
110
110
115
107
107
* Output Gear Assembly may be purchased under part number 296670
110
114
112
OUTPUT CARRIER*
104
115
103
16 OM-914207-0211-D
21
30
HOSE HOOKUP
21
41
41
69
53
32
41
69
21
41
32
20
17 OM-914207-0211-D
PARTS DRAWING
6015
2652
2037316
24
4581758
24
51
54
36
10
2
55
44
19
27
5468
3423
62
33
6
56
67
2560
1
18
68
5729
21
22
9
12
28
58
31
65
65
1
74
6111
474813
35
8
44
5
7
66
67
38
63
73
45
72
66
42
46
50
49
NOTES:
1. ITEM 1 - AIRCYLINDER KIT CONTAINS FASTENERS AND
CYLINDERS FOR CLUTCH AND BAND BRAKE.
2. ITEM 63 CONTAINS FASTENERS FOR BRAKE VALVE.
3. HOSE KIT CONTAINS FITTINGS AND HOSE.
34
1443
62
40
18 OM-914207-0211-D
PARTS LIST
ITEM QTYPART NO DESCRIPTIONITEM QTYPART NODESCRIPTION
11256131AIR CYLINDER KIT382414551BOLT-1/2-13NCX1 1/2LG HXHD,GR5/FB
21296670OUTPUT CARRIER ASSEMBLY391432018FITTING JIC O-RING EL
31296671INTERMEDIATE CARRIER ASSEMBLY401296952SPRAG BRAKE HUB ASSEMBLY
41296672INPUT CARRIER ASSEMBLY414432023FITTING JIC O-RING NIPPLE
51299748BAND BRAKE421438043BRAKE COVER
61303150LH MOUNTING ANGLE432456001FITTING-LUBE, 3/16 DRIVE FIT, SHORT
71303151RH MOUNTING ANGLE442456008FITTING-RELIEF1/8-27NPTF, 15 PSI MAX
81312574CLUTCH CYLINDER SUPPORT BRACKET451458164MOTOR-HYD, 3.21/5.78 CU.IN., 2 SPD
91324510CLUTCH461462063O-RING 2-165
101328167GEAR HOUSING COVER471462082O-RING 2-358
111330016BRAKE PISTON481462083BACK UP RING
127330017STRATOR PLATE491462084O-RING 2-362
136330018DISC-BRAKE501462085BACK UP RING
141332229DRUM511462092O-RING 2-275
151334198GEAR-SUN521462093O-RING 2-280
161334199GEAR-SUN531432053FITTING JIC O-RING NIPPLE
171334200GEAR-SUN542468041PLUG, -8 SAE, 3/4"-16 UNF
181338378END BEARING-MOTOR SIDE551468042REDUCER-3/4-16 SAE O-RING X 1/8NPTF
191338380END BEARING-GEAR SIDE561486087SEAL-OIL-SHAFT-SKF 42419
201338381HOUSING-GEAR571486088SEAL-OIL-SHAFT-SKF 38653
211414543CAPSCREW-1/2-13NCX3LG,HXHD, GR 5583490006SNAP RING 5100-125
221357529INPUT SHAFT591432054FITTING JIC SWIVEL EL
231357530SHAFT-OUTPUT602490056SNAP RING 5100-425
242362301SPACER6112494129SPRING-BRAKE
251362302SPACER-SHAFT621514023U-BOLT W/2 NUTS
261362303SPACER 80K WINCH631516048COUNTER BALANCE BLOCK
271362304SPACER
281362305SPACER655418069NUT-1/2-13NC HEX REG,Z/P
291370062YOKE-SHIFTER668414556CAPSCREW-1/2-13NCX1 3/4 HXHD GR.5
301432048FITTING JIC SWIVEL TEE6714414790BOLT-7/8-9NC X 3.25 LG,HXHD,GR8, Z/P
311402132BALL BEARING6814418108NUT-7/8-9NC HEX REG Z/P
322432049FITTING JIC BRANCH TEE691509137HOSE
331412119END BEARING BUSHING702509140HOSE
342412120DRUM BUSHING713509141HOSE
351412121END BEARING BUSHING721462081ORING 2-159
368414521CAPSCREW-1/2-13NCX1LG HXHD GR 5734414578BOLT-1/2-13NC X 1 1/4 LG, HXHD, GR 5
378414658BOLT-5/8-11NCX1 1/2LG,HXHD,Z/P,GR.5741468016PIPE PLUG 1/8-27 NPTF
19 OM-914207-0211-D
AIR CYLINDER KIT #256131 PARTS LIST
202
202
209
203
204
206
204
201
205
204
206
203
207
ITEM QTYPART NO DESCRIPTION
2011408422MOUNTING BRACKET
2022418067NUT-1/2-20NF HEX JAM
2032418223WASHER-1/2 USS FLAT
2043424005COTTER PIN- 1/8 DIA X 1 LG
2051424027CLEVIS PIN-1/2 SHAFT DIA X 1 1/2 LG
2062424205CLEVIS PIN-1/2 SHAFT DIA X 1 23/64 LG
2071433031AIR CYLINDER
2081433032AIR CYLINDER
2091448108EYE BOLT
208
20 OM-914207-0211-D
DIMENSIONAL DRAWING
CONNECT TO 2 SPEED SWITCH
SAE #16 O-RING PORT
12VDC SOLENOID
1" LINE SIZE
PAY-OUT PORT
13.00
330,20
10.21
259,21
50.61
1285,45
49.47
1256,56
20.41
518,42
GREASE ZERK
LUBRICATE AS NOTED IN
INSTRUCTION MANUAL
Ø9.00
228,60
14.81
376,18
Bolt Size
(inch es)
Thd s Per
Inch
Bolt Torque (ft-lb)
SAE Gr ade 5SAE Gra de 8
7/16145478
1/2 1378119
5/8 11154230
3/4 10257380
7/8 9382600
1 8587700
Ø21.00
533,40
25.25
641,36
23.93
607,90
SAE #16 O-RING PORT
1" LINE SIZE
PAY-IN PORT
DRUM
59.00
1498,60
C
L
8.00
203,20
4.00
101,60
CLUTCH DIS-ENGAGE PORT
1/8 NPT FITTING SIZE
CONNECT TO CLUTCH VALVE
100 PSI AIR PRESSURE MINIMUM
20.00
508,00
BAND BRAKE ENGAGE PORT
1/4 NPT FITTING SIZE
CONNECT TO BAND BRAKE VALVE
100 PSI AIR PRESSURE MINIMUM
21 OM-914207-0211-D
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 repair 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 improve its products through changes in design or materials as it may deem
desirable without being 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 representative. Bills for service, labor or other expenses that have been
incurred by the Buyer without approval or authorization by RAMSEY WINCH will not
be accepted.
See warranty card for details.
Ramsey Winch Company
Post Office Box 581510
Tulsa, Oklahoma 74158-1510
Telephone: (#918) 438-2760 FAX: (#918) 438-6688
OM-914207-0211-D
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