Ramsey HD-P8000 User Manual

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

…

PLEASE READ THIS MANUAL CAREFULLY

This manual contains useful ideas for obtaining the most efficient operation from your Rams ey 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 int o every win ch 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 ba ck page for limited warranty.

SPECIFICATIONS*

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

(Kg.) …………………………………………………

3,620 Gear Reduction 5.1:1 W eight (wit hout cable)

LAYER OF CABLE *Rated li ne pul l

per layer * Cable Capaci t y per Lay er

HD-P8 00 0 (STD. DRUM)

HD-P8000 ("Y" DRUM)

* Line S peed (at 15 GP M )

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

…………………………………………………………

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

HD-P8000 "Y" …………. …………. . 76 lbs. (34.5 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. 25 55 90 130 170 m 7 16 27 39 51 ft.15356085115 m 4 10 18 25 34 FPM5058677684 MPM 15.2 17.6 20.3 23.1 25.5

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.

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 alo ng 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 pl ate 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 hammer 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 n ut when proper setting is obtained. CAUTION: OVER-TIGHTENING OF JAM NUT MAY STRIP NYLON SETSCREW.

(UNDERWOUND APPLICATION REQUIRES CABLE TO

COME UNDER DRUM FROM OPPOSITE DIRECTION

NOTE: VIEW SHOWN WITHOUT CABLE TENSIONER FOR CLARITY.

CABLE IN DIRECTION

INSERT CABLE AS SHOWN FOR "A" ROTATION

AND INSERTED IN THIS SAME CABLE POCKET.)

OVERWOUND APPLICATION.

CABLE DRUM

ROTATION DIRECTION

"A" ROTATION

DIRECTION

SETSCREW

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.)

"B" ROTATION

DIRECTION

CABLE DRUM

ROTATION DIRECTION

CABLE IN DIRECTION

CARTRIDGE

POSITION

"A" ROTATION

PLUG

POSITION

(REEL IN) RAISE INLET

"B" ROTATION

CARTRIDGE POSITION

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 DAM AGED

10 MICRON NOMINAL FILTRATION

PORT CONTROL

WITH BRAKE RELEASE SHUTTLE

TYPICAL LAYOUT

MOTOR

BRAKE

PORT

PERFORMANCE CHARTS

LINE SPEED-FIRST LAYER (FPM)

051015

GALLONS P ER M INUTE (GPM )

BASED ON 15.5 CU. IN. MOTOR

HIGH PRESSURE LINE (.50 I.D. MINIMUM)

3 POSITION

4 WAY VALVE

(MOTOR SPOOL)

8000

7000

6000

5000

4000

3000

2000

1000

LINE PULL-FIRST LAYER (LB)

WORKING PRESSURE (PSI) AT 15 GPM

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

PUMP

MAX. FLOW & PRESSURE AT RATED LOAD: 15 GPM 2500 PSI

SYSTEM

RELIEF

1500500

1000 2000 2500

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 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 release 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 engagement 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 broken 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 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 2 if it does.

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

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