Ramsey 80K User Manual

OPERATING, SERVICE AND

MAINTENANCE MANUAL

WILDCAT SERIES 80,000 LB

INDUSTRIAL

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF

WINCH. SEE WARNINGS!

WINCH

TABLE OF CONTENTS

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

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

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

HYDRAULIC SYSTEM REQUIREMENTS ........................................................................................... 2

CABLE INSTALLATION ...................................................................................................................... 3

CLUTCH OPERATION ......................................................................................................................... 4

WINCH OPERATION ........................................................................................................................... 4

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

LUBRICATION TABLE ........................................................................................................................ 5

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

INSTRUCTIONS FOR DISASSEMBLY ................................................................................................ 6

DISASSEMBLY OF CARRIER ASSEMBLY ...................................................................................... 14

ASSEMBLY OF CARRIER ASSEMBLY ............................................................................................ 15

CARRIER ASSEMBLIES ................................................................................................................... 16

HOSE HOOKUP ................................................................................................................................. 17

PARTS DRAWING ............................................................................................................................. 18

PARTS LIST ....................................................................................................................................... 19

AIR CYLINDER .................................................................................................................................. 20

DIMENSIONAL DRAWING ................................................................................................................ 21

LIMITED WARRANTY ........................................................................................................................ 22

Lb

30 9

36 11

42 13

48 15

54 16

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

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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

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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

your climate.

3. Inspect winch for damage and wear.

4 OM-914207-0211-D

LUBRICATION TABLE

LubricantDescription*

80W140Synthetic ‐25(‐32) 125(52) 225(107)
75W90Synthetic ‐40(‐40) 115(46) 215(102)
80W90Conventional ‐20(‐29) 100(38) 180(82)
85W140Conventional 20(6) 120(50) 200(93)

*UseAPIGL‐5orEPlubricants.

TROUBLE SHOOTING GUIDE

Min

Ambient&

Operating

TempRangeF(C)

Max

Ambient

MaxOperating

CONDITIONS POSSIBLE CAUSE CORRECTION

OIL LEAKS FROM WINCH

WINCH RUNS TOO SLOW

CABLE DRUM WILL NOT

FREESPOOL

BRAKE WLL NOT HOLD

BRAKE WILL NOT RELEASE

1. Seals damaged or worn.

2. Too much oil.

3. Damaged o-rings.

4. Case drain not connected.

1. Low flow rate.

2. Hydraulic motor worn out.

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