Ramsey REP-6000, REP 8000, REP 9000 User Manual
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.
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.
2
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.
3
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
4
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
5
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