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 your vehicle up or ease your
vehicle down a steep grade, it will also pull another vehicle
or a load while your vehicle is anchored in a stationary
position. The sketches on this page show you a few
techniques.
For basic self-recovery, anchor to a tree or heavy rock.
When anchoring to a tree, always use a tree trunk
protector.
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 don’t
overtake the winch line. Plan your pull. You can’t always
hook up and pull out in one step. Examine all the areas for
anchoring possibilities as well as leverage situations,
direction, and goal.
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.
For a direct pull of 2000 lbs., hitch truck to a tree or solid anchor,
and take out of gear.
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.
To double the pull, use 2-part line and tie off to chassis.
Take out of gear.
3
Installation
The winch shown in this owners manual is solely and
exclusively designed for vehicle mounted, non-industrial
applications. All other applications will void warranty.
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 lockwashers through mounting holes in
channel and into hardware in winch feet (see FIGURE 1).
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 Pro Plus 6000/8000 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 channel be used in all non-Ramsey mounting.
CONNECT RED CABLE
CONNECT BLACK GROUND CABLE
TO NEGATIVE (-) TERMINAL
OF VEHICLE BATTERY.
TO POSITIVE (+) TERMINAL
OF VEHICLE BATTERY.
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).
TO ENSURE PROPER ALIGNMENT
OF THE ROLLER FAIRLEAD TO THE
DRUM, POSITION SMALLER (7/16") SET
OF HOLES AT BOTTOM FOR MOUNTING.
DETAIL A
ROLLER FAIRLEAD
CONTROL SWITCH
RECEPTACLE
CLUTCH
SHIFTER KNOB
HAWSE FAIRLEAD
(SEE DETAIL A
FOR MOUNTING
ROLLER FAIRLEAD)
COTTER PIN
MOUNTING
CHANNEL
FAIRLEAD MOUNTING BOLT
3/8-16NC X 1-1/4 LG.
CABLE HOOK
CLEVIS PIN
WINCH MOUNTING BOLT
3/8-16NC X 1-1/4 LG.
FIGURE 1
4
Operating Instructions
The winch clutch allows rapid unspooling of the
wire rope 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 into 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 battery 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 (See Figure 1).
The remote control switch is water proof. It has
push buttons 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 directions. Snap appropriate “IN” and
“OUT” disc into proper thumb cavity. Do not
leave switch plugged in when winch is not in use.
MAINTENANCE
All moving parts are permanently lubricated with
high temperature lithium grease at the time of
assembly. Under normal conditions factory
lubrication will suffice.
Lubricate cable periodically using light
penetrating oil. Inspect the cable for broken
strands and replace if necessary. If the cable
becomes worn or damaged, it must be replaced.
Corrosion on electrical connections will reduce
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.
To minimize corrosion of the internal motor
components that may occur due to condensation,
power the winch in or out periodically. Energizing
the motor will generate heat, which will help
dissipate any moisture buildup in the motor. This
should be performed at periodic intervals (such
as will each oil change of your vehicle). Note:
Refer to the Troubleshooting Guide if the motor
has be submerged.
Cable Installation
1. Unwind the new cable by rolling it out along
the ground to prevent kinking.
2. Remove old cable and observe the manner
in which it is attached to the cable drum
flange.
3. Before installing the new cable assembly,
securely wrap the end of the cable with
plastic tape or similar tape to prevent fraying.
4. Position the cable drum so that the large
13/32” diameter hole in the motor end drum
flange is approximately on the top.
5. 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.
6. Secure the cable to the drum flange using
cable anchor and capscrew shown in the
parts drawing on page 7 (Item # 34 and 22).
Securely tighten the capscrew, but do not
over-tighten.
7. 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.
5
Ramsey Electric Winches Trouble Shooting Guide
Jar each solenoid to free contacts. Check each
Jar solenoid to free contacts. Check solenoid
CONDITIONS POSSIBLE CAUSE CORRECTION
MOTOR RUNS IN ONLY ONE Defective solenoid or stuck solenoid.
DIRECTION solenoid by applying 12 volts 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 Long period of operation Cooling-off periods are essential to prevent
HOT 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
INSUFFICIENT POWER, and grease
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 symptoms still exist, it
DOES NOT TURN will be necessary to disassemble winch to
determine cause and repair.
---------------------------------------------------------------------------------------------------------------------------------------------------------------MOTOR WILL NOT OPERATE Defective solenoid or stuck solenoid.
by applying 12 volts 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.
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
from high pressure car wash motor without a load in short bursts to dry
windings.
------------------------------------------------------------------------------------------------------------------------------------------------------------------
6
NOTES
NOTES
OM-914082-0103
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