Ramsey REP-6000, REP 8000, REP 9000 User Manual

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Ramsey Winch Company
LINE S PEED
(FPM)
CURRENT
(AMPS)
(lbs) (kg) 12V 12V LAYER FT.* M*
0 0 25 70 1 20 6
1,000 450 21 155 2 50 15
3,000 1,350 16 240 3 80 24
5,000 2,260 10 370 4 100 30
6,000 2,710 8 440
REP 6000
PERFORMANCE FI RST LAYER OF CABLE
LINE PULL
(1/4" (6 MM ) DIA. CABLE)
CUMULATI VE BY LAYER
CABLE DRUM CAPACIT Y
* DEPENDS ON CABLE BEING UNIFORMLY W OUND ONTO DRUM.
LINE S PEED
(FPM)
CURRENT
(AMPS)
(lbs) (kg) 12V 12V LAYER FT.* M*
0 0 18 60 1 15 4
2,000 900 15 150 2 40 12
4,000 1,810 12 220 3 70 21
6,000 2,710 9 310 4 95 28
8,000 3,620 6 420
* DEPENDS ON CABLE BEING UNIFORMLY W OUND ONTO DRUM.
REP 8000
PERFORMANCE FI RST LAYER OF CABLE
CABLE DRUM CAPACIT Y
LINE PULL
(5/16" (8 MM ) DIA. CABLE)
CUMULATI VE BY LAYER
(lbs) (kg) 12V 24V 12V 24V LAYER FT.* M*
0 0 33 25 97 35 1 15 4
2,000 900 17 15 180 75 2 40 12
4,000 1,810 13 11 260 110 3 70 21
6,000 2,710 11 9 335 140 4 95 28
9,000 4,070 8 7 420 175
LINE S PEED
(FPM)
CURRENT
(AMPS)
LINE PULL
(5/16" (8 MM ) DIA. CABLE)
CUMULATI VE BY LAYER
REP 9000
PERFORMANCE FI RST LAYER OF CABLE
CABLE DRUM CAPACIT Y
* DEPENDS ON CABLE BEING UNIFORMLY W OUND ONTO DRUM.
OWNER’S MANUAL
Front Mount Electric Winches
Model REP 6000
Model REP 8000
Ramsey performance data is compiled from actual winch testing
Congratulations
You have purchased the finest winch avail­able in its service class. The REP 6000, REP 8000 and REP 9000 feature a highly efficient 3 stage planetary gear set. The REP 6000 and REP 8000 transmit torque from a perma­nent magnet D.C. motor, while the REP 9000 utilizes a series wound D.C. motor. A safe positive clutch allows free spooling for quick cable deployment. An automatic load holding brake is designed to hold the full rated capacity of the winch. It was designed and manufactured to provide you with the utmost in utility. As with any device that combines power and movement in its use, there are dangers if improperly used. At the same time, there are easier and faster ways for getting the job done if certain precautions are taken first. Please read this manual carefully. It contains useful ideas in obtaining the most efficient operation from your Ramsey Winch and safety procedures you need to know
CAUTION: Read and understand this manual before installation and operation of winch. See Safety Precautions.
Model REP 9000
Contents
Safety Precautions ..............................2
Tips for Safe Operation........................2
Techniques of Operation......................3
Installation ......................................4-5
Electrical Connections & Operations ....8
Maintenance ......................................8
Operating Instructions ........................9
Trouble Shooting Guide ....................10
Winch Parts List ..........................11-15
Warranty..............................Back Cover
before beginning use. When you follow our guidelines for operation, your Ramsey Winch will give you many years of satisfying serv­ice. Thank you for choosing Ramsey. You will be glad you have one working for you.
Please Note: Ramsey REP6000, REP8000 and REP9000 Series winches are designed for front mount vehicle use. The winches are not designed for and should not be used in industrial applications (car haulers/carriers, wreckers, hoisting, etc.), and Ramsey does not warrant them to be suitable for such use. Ramsey makes a separate, com­plete line of winches for industrial/commercial use. Please contact the factory for further information.
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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 in 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. Don't step over a cable, or near a cable under
load.
C. Use supplied hook strap when handling hook
for spooling wire rope.
D. Don't move the vehicle to pull a load on the
winch cable. This could result in cable break­age.
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 one minute at or near rated load. Do not maintain power to the winch if the motor stalls. Electric winches are for intermittent usage and should not used in constant duty applications.
J. Disconnect the remote control switch from the
winch when not in use. A Ramsey Part No. 282053 safety on-off switch in your vehicle is recommended.
K. Note: Do not use winch in hoisting applica-
tions due to required hoist safety factors and features.
L. Do not exceed maximum line pull ratings
shown in tables. Shock loads must not exceed these ratings.
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 switch 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 in cable under power using supplied hook strap.
Tips for Safe Operation
Don't 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 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 illustra­tions.
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.
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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 (remember, you must leave 5 wraps min. on the drum). If this is not practical, use a snatch block and double line arrangement (see illustration).
Neat, tight spooling avoids cable binding, which is caused when a load is applied and the cable is pinched between two others. 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.
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 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 direct pull of 2000 lbs., hitch truck to a tree or solid anchor, and take out of gear.
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 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 following sketches show you a few 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.
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 with snatch block and tie off to chassis. Take out of gear.
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.
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Installation
The winches shown in this owner's manual are solely and exclusively designed for vehicle mount­ed, non-industrial applications. All other applica­tions will void warranty.
Note: For specific bull-bar applications, the shifter lever on the winch may need to be repositioned. Refer to pages 6-7 for instructions in how to do this.
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 REP winches 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 a Ramsey mounting channel be used in all non­Ramsey mountings.
Note: See the following separate sections for attaching the wiring to the motor and solenoid for the REP 6000/8000, REP 9000 12V, and REP 9000 24V models. The combined installation instructions resume on the following page.
clamp to attach solenoid assembly to winch motor (see FIGURE 2). Position solenoid at about a 45° angle for clearance of lower winch guard tube of kit. TIGHTEN CLAMP SECURELY.
FIGURE 2
REP 9000 12V
When mounting winch, connect labeled motor leads coming from solenoid assembly to appro­priately marked motor terminals. TIGHTEN NUTS ON MOTOR TERMINALS SECURELY (see FIGURE
3). Attach solenoid ground wire to grounding bolt located at bottom of motor (Battery ground wire is already installed to grounding bolt on motor.)
Use solenoid clamp, as shown in FIGURE 2, to secure solenoid assembly to winch motor. If installing in combo mounting kit, position at about a 45° angle for clearance of lower winch guard tube in kit. Be sure that clamp is clear of motor terminals at bottom of motor. TIGHTEN CLAMP SECURELY.
REP 6000/8000
When mounting winch, attach solenoid wires to motor terminals at end of motor. TIGHTEN NUTS ON MOTOR TERMINALS SECURELY (see FIGURE
1). Attach solenoid to mounting holes at end of long channel (see FIGURE 1) or use solenoid
FIGURE 1
FIGURE 3
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REP 9000 24V
When mounting winch, connect labeled motor leads coming from solenoid assembly to appro­priately marked motor terminals. TIGHTEN NUTS ON MOTOR TERMINALS. Attach solenoid ground to #10 Capscrew located on vertical sur face of motor end bearing (See FIGURE 4). Use solenoid clamp, as shown in FIGURE 2, to secure solenoid assembly to winch motor. If installing in combo mounting kit, position at about a 45° angle for clearance of lower winch guard tube in kit. Be sure that clamp is clear of motor terminals at bot­tom of motor. TIGHTEN CLAMP SECURELY.
Hole for Solenoid Ground Wire Bolt
Attach fairlead to channel using hard­ware furnished with winch (see FIG­URE 5). Attach winch to channel. Place (4) flat washers and nuts into pockets of winch mounting feet and thread capscrews with lock washers through mounting holes in channel and into hardware in winch feet.
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 drum cable through fair­lead and attach cable hook. Use clevis pin and cotter pin (see FIGURE 5).
Motor Terminals
FIGURE 4
FIGURE 5
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Repositioning Shifter for Specific Bull Bar Applications
Note: The shifter is positioned correctly for most applications. It will only need to be repositioned as
necessary for specific bull bar applications.
Refer to the Parts List and Exploded Parts Diagram for your specific winch elsewhere in this owner’s manual.
1. Position winch as shown in Figure 6. Remove screws from tiebars. You may be able to loosen the screws at the motor end without removing them. Pull the Gear Housing assembly from the drum and shaft and set it down on the work bench with the Gear Housing Cover up. Remove the drum bushing from the Gear Housing assembly or the end of the drum. Set aside.
2. Remove (6) capscrews from the Gear Housing Cover. Holding the Gear Housing Cover over the Gear Housing assembly, flip it over and set it on the workbench.
FIGURE 6
3. Gently lift the Gear Housing assembly, working the gears, bushings, etc. that are inside the Gear Housing out so that they are left stacked on the workbench. See Figure 8.
4. Turn the Gear Housing assembly over and set on workbench. Remove the Retainer (item #37) by removing six capscrews (item #21) from Gear End Bearing (item 13). Once the retainer is removed, the Ring Gear (item #10), Cam Ring (item #36), and Locking Ring (item #34) can be lifted off the end bearing.
Remove the six springs (item #38) from the end bearing.
FIGURE 7
6
FIGURE 8
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5. Determine position shifter knob needs to
be for your application. Note: Shifter knob cannot be positioned too low or it will interfere with the feet on the Gear End Bearing (see Range of Position in Figure 9).
6. To position the shifter knob, place lock-
ing ring in end bearing with stop post
approximately 180° from where shifter knob needs to be positioned. Place cam
ring over locking ring in proper position and confirm that shifter knob will move from engaged to disengaged position without interference. Mark position of stop post on end bearing.
7. Remove cam ring and locking ring from end bearing. Insert springs (item #38) into end bearing.
When you replace the locking ring (item #34) over the springs, be sure the springs compress down into their recesses, and don’t bend sideways.
8. Reassemble Gear Housing as shown in Figure 7. Make sure locking ring is positioned with stop
post at marked location. The capscrews (item #38) for the retainer should be tightened to 40-45 in­lbs. Do not over-tighten.
9. Place Gear Housing over the stacked gears, etc. that you removed in step 3. Gently work the hous-
ing over the stack, turning it as needed to mesh the planetary gears with the ring gear in the hous­ing. Once they are all in the housing, flip the assembly over. Align the Gear Housing Cover and gas­ket with the holes in the ring gear. Replace the (6) capscrews that hold the Gear Housing Cover onto the Gear Housing. Tighten securely.
10. Move the Shifter to the Disengaged position.
11. Turn the Gear Housing over and set it on the
work bench with the Gear Housing Cover down. See Figure 10.
12. Install the drum bushing into the Gear
Housing, confirming that the slot in the bush­ing is aligned with the key in the end bearing. Pick up the rest of the winch (drum and motor end), and holding the drum, lower the winch onto the gear end. Stab the shaft into the gear end--you may need to turn the drum slightly to get the shaft to go all the way in.
13. Place the tiebars on the motor end and gear
end and fasten using (4) screws. Tighten securely.
14. Once the winch is reassembled, turn it so
that it is sitting on its feet. Confirm that the cable will freespool when the shifter is in the Disengaged position. Connect up the winch temporarily and confirm that the cable spools when the shifter is in the Engaged position.
FIGURE 9
FIGURE 10
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FIGURE 11
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.
REP-6000/REP-8000/REP 9000 12V Electrical Connections
Route red and black 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 and black cable to negative (-) terminal.
REP-9000 24V Electrical Connections
Route battery cable 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 (see Figure 3). Connect black ground cable to negative (-) terminal of bat­tery and to winch mounting bolt on motor end of winch (see Figure 6 on following page).
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 black solenoid 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. DO NOT LEAVE SWITCH PLUGGED IN WHEN WINCH IS NOT IN USE.
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.
Maintenance
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 cable periodically using light penetrating oil. Inspect for broken strands and replace if necessary with Ramsey part number listed in Parts List. 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, make sure end of cable is squarely cut and wrapped with tape to prevent fraying. Form a short 90° bend (approximately ½") on end of the cable.
Position the cable drum so that the large 13/32" diameter hole in the motor end drum flange is approximately on the top. Insert the bent end of cable into the 13/32" hole in the drum flange and then carefully run the winch in the "reel in" direc­tion approximately ¾ revolution until the ¼" diam-
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eter 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. Securely tighten the capscrew, but do not over­tighten.
Wind 5 wraps of cable onto the drum. Winch 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 block between the cable hook and the load.
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 tab located on the gear-housing end of the winch as follows:
1.To disengage the clutch, move the clutch shifter
tab to the "OUT" position. Wire rope may now be free-spooled off the drum.
2.To engage the clutch, move the clutch shifter
tab into the "IN" position. The winch is now ready for pulling.
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Ramsey Electric Winches Troubleshooting Guide
CONDITION
MOTOR RUNS IN ONLY ONE DIRECTION
MOTOR RUNS EXTREMELY HOT
MOTOR RUNS, BUT WITH INSUFFICIENT POWER, OR WITH LOW LINE SPEED
MOTOR RUNS, BUT DRUM DOES NOT TURN
MOTOR WILL NOT OPERATE
MOTOR WATER DAMAGED
CABLE DRUM WILL NOT FREESPOOL OR IS DIFFICULT TO FREESPOOL
POSSIBLE CAUSE
(1) Defective solenoid or stuck solenoid
(2) Defective remote control switch
(1) Long period of operation
(1) Insufficient battery
(2) Bad connection
(3) Insufficient charging system
(1) Clutch not engaged
(1) Defective solenoid or stuck solenoid
(2) Defective remote control switch
(3) Defective motor
(4) Loose connections
(1) Submerged in water or water from high pressure car wash
(1) Clutch not disengaged
(2) Winch not mounted squarely caus­ing end bearing to bind drum
(3) Some or all of the (6) 414861 flat head capscrews attaching the 479007 ring gear retainer are too tight
CORRECTION
(1) Jar solenoid to free contacts. Check by applying 12 volts to coil terminal (it should make an audible click when energized)
(2) 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
(1) Cooling-off periods are essential to prevent overheating
(1) Check battery terminal voltage under load. If 10 volts or less, replace or parallel another battery to it
(2) Check battery cables for corrosion; clean and grease
(3) Replace with larger capacity charging system
(1) If clutch engaged but symptom still exists, it will be necessary to disassemble winch to determine cause and repair
(1) Jar solenoid to free contacts. Check solenoid by apply­ing 12 volts to coil terminal (it should make an audible click when energized) (2) 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.
(3) If solenoids operate, check for voltage at armature post; replace motor
(4) Tighten connections on bottom side of hood and on motor
(1) Allow to drain and dry thoroughly, then run motor with­out load in short bursts to dry windings.
(1) Check clutch operation according to nameplate. Make sure clutch shifter knob is fully at “OUT” position.
(2) Check mounting to see that installation instructions on page 4 have been followed.
(3) Remove the gear housing cover, 413018, and all gears from inside the gear housing. Disengage the clutch and check to see that the ring gear will rotate by hand. If it will not, using a hex (allen) wrench, slightly loosen all the cap­screws and then snugly re-tighten them in cross-cross pat­tern, but do not over tighten. The ring gear must rotate by hand. Re-assemble the winch.
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REP 6000
REP 6000 PARTS LIST
Item
No.
Qty. Parts No. Descr iption
Item
No.
Qty. Parts No. Descr iption
1 1 247009 Gear Carrier As s’y.—Input 20 6 416273 Sc rew #6—32NCx3/8 Lg. Fil. Hd. 2 1 247007 Gear Carrier As s’y—Intermediate 21 4 418018 Nut 1/4—20NC Hx. Reg. E lastic Stop 3 1 247008 Gear Carrier As s’y—Out put 22 4 418035 Nut 3/8—16NC Hx. Reg. Z/P 4 1 251110 Switch Ass’y 23 4 418177 Loc kwasher 3/ 8 ID Med. Sect. Plated 5 1 251228 Cable Assem bly-100’ 1/4” (6MM) Dia. 24 4 418181 W asher—Flat 3/8 ID S.A.E., Plated 6 1 278154 Solenoid Ass’y 25 1 424023 Clamp 7 1 296181 Brake/Shaft Ass ’y 26 1 442207 Gas ket 8 1 332128 Drum—Cable 27 1 444048 Gear—O utput, Sun
9 1 334143 Gear—Ring 28 1 448071 Cable Anc hor 10 1 334147 Gear—Interm ediate, Sun 29 2 448049 Tie Bar 11 1 334154 Gear—Input, Sun 30 1 458109 Motor/End Bearing As s’y. 12 1 338249 End Bearing 31 1 470053 Roll P in 1/8 Dia. x 3/8 13 2 412056 Bus hing—Drum 32 1 477002 Loc king Ring 14 1 412061 Bus hing—Shaft 33 1 477003 Cam Ring 15 1 413018 Cover—Gear Housing 34 2 477004 Ring— Half 16 4 414316 Caps crew 3/8—16NCx1-1/4Lg.Hx.Hd.Gr.5,Z/P 35 1 479007 Ret ainer—Ring Gear 17 4 414829 Caps crew 1/4—20NCx1 Lg. Soc . Button Hd. 36 6 494077 Spring 18 1 414830 Caps crew 1/4—20NCx3/8 Lg. Soc . Button Hd. 37 3 518020 Thrust Washer 19 6 414861 Caps crew 1/4—20NCx3/4 Lg. Flat Hd. Soc . NYLOK 38 1 518027 Thrust Disc
Hawse Fairlead
Replacement Kit #251152
Included with: REP 6000 H
Roller Fairlead
Replacement Kit #251183
Included with: REP 6000 R
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REP 8000
REP 8000 PARTS LIST
Item
No.
Qty. Parts No. Descr iption
Item
No.
Qty. Parts No. Descr iption
1 1 247004 Gear Car rier Ass’y.—Input 20 6 416273 Sc rew #6—32NCx3/8 Lg. F il. Hd.
2 1 247007 Gear Car rier Ass’y—Intermediate 21 4 418018 Nut 1/4—20NC Hx. Reg. Elastic Stop
3 1 247008 Gear Car rier Ass’y—Output 22 4 418035 Nut 3/8—16NC Hx. Reg. Z/P
4 1 251110 Switch Ass’y 23 4 418177 Lockw asher 3/8 ID Med. Sect. P lated
5 1 251118 Cable Assembly-95’ 5/ 16” (8MM) Dia. 24 4 418181 Was her—Flat 3/8 ID S.A.E., P lated
6 1 278155 Solenoid Ass ’y 25 1 424023 Clamp
7 1 296181 Brake/Shaft Ass’y 26 1 442207 Gas ket
8 1 332128 Dr um—Cable 27 1 444048 Gear—O utput, Sun
9 1 334143 Gear—R ing 28 1 448046 Cable Anchor 10 1 334147 Gear— Intermediate, Sun 29 2 448049 Tie Bar 11 1 334153 Gear— Input, Sun 30 1 458109 Motor/End Bear ing Ass’y. 12 1 338249 E nd Bearing 31 1 470053 Roll P in 1/8 Dia. x 3/8 13 2 412056 B ushing—Dr um 32 1 477002 Loc king Ring 14 1 412061 B ushing—Shaft 33 1 477003 Cam Ring 15 1 413018 C over—Gear Housing 34 2 477004 Ring— Half 16 4 414316 C apscrew 3/8—16NCx1-1/4Lg. Hx.Hd.Gr.5,Z/P 35 1 479007 Retainer —Ring Gear 17 4 414829 C apscrew 1/4—20NCx1 Lg. Soc . Button Hd. 36 6 494077 Spring 18 1 414830 C apscrew 1/4—20NCx3/8 Lg. S oc. Button Hd. 37 3 518020 Thrust Washer 19 6 414861 C apscrew 1/4—20NCx3/4 Lg. Flat Hd. Soc. NYLOK 38 1 518027 Thrust Disc
Hawse Fairlead
Replacement Kit #251152
Included with: REP 8000 H
Roller Fairlead
Replacement Kit #251183
Included with: REP 8000 R
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REP 9000
REP 9000 PARTS LIST
Item
No.
Qty. Parts N o. De scription
Item
No.
Qty. Parts N o. Descr iption
1 1 247009 Gear Car rier Ass ’y.—Input 23 4 418035 Nut 3/8— 16NC Hx. Reg. Z/P 2 1 247022 Gear Car rier Ass ’y—Intermediate 24 4 418040 Nut 3/8—24NC Hx. Reg. Z/P 3 1 247023 Gear Car rier Ass ’y—Output 25 5 418177 Lockwas her 3/8 Med. Sect. Z/P 12V 4 1 278158 Solenoid Ass ’y—12V 8 418177 Lockw asher 3/8 Med. Sect. Z/P 24V
1 278096 Solenoid Ass ’y—24V 26 5 418181 Was her—Flat 3/8 ID S.A.E. Z/P 5 1 251110 Sw itch Ass ’y 27 1 424023 C lamp 6 1 296181 Br ake/Shaft Ass’y— 12V 28 1 442208 Gasket—C over
1 296385 Brake/S haft Ass’y—24V 29 1 444077 Gear—Ring, Input 7 1 328138 Cover —Gear Housing 30 1 448046 C able Anchor 8 1 332193 Dr um—Cable 31 2 448049 Tie Bar 9 1 334154 Gear—Input Sun 32 1 450001 Key—24V.
10 1 334147 Gear—Intermediate Sun 33 1 458114 Motor—Electr ic 12V 11 1 334170 Gear—Output Sun 1 458005 Motor—Elec tric 24V 12 1 334171 Gear—Ring, Out put 34 1 470053 Roll Pin 1/8 D ia. x 3/8 Lg. 13 1 338332 End Bearing 35 1 477002 Loc king Ring 14 1 296534 End Bearing—Motor—12V 36 1 477003 C am Ring
1 338282 End Bear ing—Motor—24V 37 2 477004 Ring—Half
15 2 412056 Bushing—D rum 38 1 479007 Retainer—R ing Gear 16 1 412061 Bushing—S haft 39 6 494077 Spring 17 4 414316 Capsc rew 3/8—16NCx1-1/ 4Lg.Hx.Hd.Gr.5,Z/P 40 6 518020 Thrus t Was her 18 4 414823 Capsc rew 1/4—20NCx1 Lg. S oc. Button Hd. 41 1 518027 Thrus t Disc 19 1 414830 Capsc rew 1/4—20NCx3/8 Lg. S oc. Butt on Hd. 42 1 251118 Cable Ass embly 20 6 414868 Capsc rew 1/4—20NCx2-1/ 2 Lg. Flat Hd. Soc. NYLOK 43 1 289141 C able—Ground 21 6 414861 Capsc rew 1/4—20NCx3/4 Lg. F lat Hd. Soc. NYLOK 44 1 442219 Gasket 22 4 418018 Nut 1/4—20NC Hx. Elastic Stop 45 1 414370 Caps crew 3/8- 24NF x 1/2 HX HD ZP GR5
46 1 416212 Scr ew #10-24NC x 3/8 Lg Hx Soc Hd ZP
13
Page 14
Solenoid Assembly Parts List REP 6000/REP 8000
Item
No.
Qty.
Req'd
Part No. Description
1 2 289168 Wire Assembly—Black 4 Ga. x 6” Lg. 2 1 289090 Wire Assembly—Black 10 Ga. x 3” Lg 3 1 289091 Wire Assembly—Black 16 Ga. x 1-1/2” Lg 4 1 289169 Wire Assembly—Black 4 Ga. x 3-1/2” Lg 5 2 364002 Strap—Copper 6 1 408102 Bracket 7 1 413024 Cover—Solenoid 8 3 414053 Capscrew 1/4—20NCx1-1/4Lg.Hx.Hd. Z/P
9 7 416216 Screw #10—24NCX 1/2” Lg. Rd. Hd. Z/P 10 2 416227 Screw #10—24NCX 3/4” Lg. Truss Hd. Black 11 6 418004 Nut—Hx. Reg. #10—24NC Z/P 12 6 418014 Nut—Hx. Reg 1/4—20NC Z/P 13 4 418140 Washer #10 SAE Flat Z/P 14 2 418141 Lockwasher #10 Med. Sect. Z/P 15 3 418149 Lockwasher 1/4 Med. Sect. Z/P 16 1 418165 Washer 5/16 Shakeproof External Teeth 17 3 418411 Nutsert #10—24NC 18 3 418514 Spacer 19 1 430013 Connector Female—Molded 20 2 440071 Terminal Tab 21 2 440110 Solenoid 22 1 440111 Strap—Copper 23 1 289015 Wire Assembly—Battery Red 72” (REP 6000)
1 440112 Wire Assembly—Battery Red 60” (REP 8000)
24 1 289141 Wire Assembly—Battery Red 72” (REP 6000)
1 440113 Wire Assembly—Battery Red 60” (REP 8000)
25 1 482029 Cover—Female Connector
278154—REP 6000 278155—REP 8000
Note: All unidentified hardware comes
supplied with the solenoid.
14
Page 15
Solenoid Assembly Parts List REP 9000
Item
No.
Qty.
Req'd
Part No. Description
1 1 289015 Battery Cable 2 1 289091 Wire Assem bly—Black 16 Ga. x 1-1/2” Lg. 3 1 289092 Wire Assem bly—Black 6 Ga. x 3-1/2” Lg 4 3 289171 Wire Assem bly—Motor Lead—12V
3 289115 Wire Ass embly—Motor Lead—24V
5 1 289208 Wire Assem bly—Ground 12v
1 289209 Wire Ass embly—Ground 24v 6 2 364002 Strap—Copper 7 1 408102 Bracket 8 1 413024 Cover—Solenoid 9 3 414053 Caps crew 1/4—20NCx1-1/4Lg.Hx.Hd. Z/P
11 7 416216 Screw #10—24NCX 1/2” Lg. Rd. Hd. Z/P 12 2 416227 Screw #10—24NCX 3/4” Lg. Truss Hd. Black 13 6 418004 Nut—Hx. Reg. #10—24NC Z/P 14 6 418014 Nut—Hx. Reg 1/4—20NC Z/P 16 3 418140 Washer #10 SAE Flat Z/P 17 2 418141 Lockwasher #10 Med. Sect. Z/P 18 3 418149 Lockwasher 1/4 Med. Sect. Z/P 20 3 418411 Nutsert #10—24NC 21 3 418514 Spacer 22 1 430013 Connector Female—Molded 23 2 440071 Terminal Tab 24 2 440110 Solenoid—12V
2 440114 Solenoid—24V
25 1 440111 Strap—Copper 26 1 482029 Cover—Female Connector
278158—12V 278096—24V
Note: All unidentified hardware comes
supplied with the solenoid.
15
Page 16
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