Ramsey REP 8000, REP 9000 User Manual [en, de, es, fr]
REP 8000
REP 9000
Owner’s Manual
Front Mount Electric Winch
12 & 24 volt
English . . . . . . . . . . . . . . . . . . . . . . . .1
Français . . . . . . . . . . . . . . . . . . . . . .15
Deutsch . . . . . . . . . . . . . . . . . . . . . .29
Español . . . . . . . . . . . . . . . . . . . . . .43
Ramsey Winch Company
P.O. Box 581510 - Tulsa, OK 74158-1510 USA - Phone: (918) 438-2760 - Fax (918) 438-6688
Visit us at http://www.ramsey.com
OM-914118-0309-K
Congratulations
You have purchased the finest winch available in its service
class. The REP 8000 and REP 9000 feature a highly efficient
3 stage planetary gear set. The REP 8000 and 9000 transmits
torque from 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.
This winch 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 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 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.
Ramsey Winch Company
OWNER’S MANUAL
Front Mount Electric Winches
Contents
Safety Precautions ................................................2
Tips for Safe Operation..........................................2
Techniques of Operation ........................................3
Installation ........................................................4-7
Electrical Connections & Operations ......................5
Maintenance..........................................................8
Operating Instructions ..........................................8
Trouble Shooting Guide..........................................9
Winch Parts List ............................................10-12
Warranty ............................................................13
CAUTION: Read and understand this manual before installation and operation of winch. See Safety Precautions.
Model REP 8000 12 volt
Model REP 9000 12 and 24 volt
REP 8000 CE
Layer of Cable 1234
(lbs) 8,000 6,500 5,500 4,800
(kg) 3,620 2,940 2,490 2,170
(ft) 15 40 70 95
(m) 4 12 21 28
(lbs) 0 2,000 4,000 6,000 8,000
(kg) 0 900 1,810 2,720 3,620
(FPM)
36 15 12 8 5
(MPM)
10.9 4.5 3.6 2.4 1.5
Amp Draw 87 168 258 320 405
REP 9000 CE
Layer of Cable 1234
(lbs) 9,000 7,300 6,200 5,400
(kg) 4,070 3,300 2,800 2,440
(ft) 15 40 70 95
(m) 4 12 21 28
(lbs) 0 2,000 4,000 6,000 9,000
(kg) 0 900 1,810 2,720 4,070
(FPM) 12V
33 17 13 11 8
24V 25 15 11 9 7
12V
10 5.1 3.9 3.3 2.4
24V 7.6 4.5 3.3 2.7 2.1
12V
97 180 260 335 420
24V 35 75 110 140 175
* Depends on cable being uniformly wound onto drum.
Amp Draw
Rated Line Pull Per Layer
Cumulative Cable Cap. Per
Layer*
5/16" (8mm) dia. Cable
Line Speed First Layer
Rated Line Pull Per Layer
Line Pull First Layer
Line Pull First Layer
Line Speed First Layer
Cumulative Cable Cap. Per
Layer*
5/16" (8mm) dia. Cable
(MPM)
English
1
2
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 intermit-
tent usage and should not used in constant duty
applications.
J. Disconnect the remote control switch from the winch when
not in use.
K. Note: Do not use winch in hoisting applications 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.
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.
3
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.
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 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.
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.
4
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 7-8 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") #251126 (black), medium
length (30.00") #251127 (black) and long length (36.00")
#251128 (black). It is recommended that a Ramsey mounting
channel be used in all non-Ramsey mountings.
Note: See the following separate sections for attaching the
wiring to the motor and solenoid for the REP 8000, REP 9000
12V, and REP 9000 24V models. The combined installation
instructions resume on the following page.
REP 8000/9000 12V
When mounting winch, connect labeled motor leads coming from
solenoid assembly to appropriately marked motor terminals as
shown in FIGURE 3. TIGHTEN NUTS ON MOTOR TERMINALS
SECURELY (see FIGURE 2). 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 1, 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 9000 24V
When mounting winch, connect labeled motor leads coming from
solenoid assembly to appropriately marked motor terminals as
shown in FIGURE 4. TIGHTEN NUTS ON MOTOR TERMINALS.
Attach solenoid ground to #10 Capscrew located on vertical surface of motor end bearing (See FIGURE 4). Use solenoid clamp,
as shown in FIGURE 1, 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.
FIGURE 1
FIGURE 2
A
A
View A-A
A
1
2
A
A
View A-A
A
1
2
REP 9000 12V
REP 8000
Hole for Solenoid
Ground Wire Bolt
AA
View A-A
A
1
2
REP 9000 24V
FIGURE 4
FIGURE 3
Fairlead and Winch
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).
Electrical Connections and Operations
See the installation instructions for the Safety On/Off switch,
Part No. 282062 (12V) or 282063 (24V) as applicable, supplied with the winch, to install the On/Off switch.
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-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
2). Connect black ground cable to negative (-) terminal of battery and to winch mounting bolt on motor end of winch (see
Figure 6).
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.
5
FIGURE 5
TO ENSURE PROPER ALIGNMENT
OF THE ROLLER FAIRLEAD TO THE
DRUM, POSITION SMALLER (7/16") SET
OF HOLES BY BOTTOM FOR MOUNTING
FIGURE 6
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 7. 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.
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 9.
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.
6
3
28
1
23
2
40
10
40
17
41
16
12
29
11
39
21
13
38
36
34
10
37
FIGURE 7
FIGURE 9
FIGURE 8
7
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 10).
6. To position the shifter knob, place locking 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 9. Make sure locking ring is positioned with stop post at marked location.
The capscrews or the retainer should be tightened to 40-45 in-lbs. Do not over-tighten.
9. Place Gear Housing over the stacked gears, etc. that you removed in step 3. Gently work the housing 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 11.
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.
FOR SHIFTER KNOB
RANGE OF POSITION
KNOB
SHIFTER
CAM RING
RING GEAR LOCK
STOP POST ON
END BEARING
FIGURE 10
FIGURE 11
8
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.
Corrosion on electrical connections will reduce performance
or may cause a short. Clean all connections especially in the
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 with each oil
change to your vehicle). Note: Refer to the Troubleshooting
Guide if the motor has been submerged.
Cable Installation
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" long) in the 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 3/4 revolution until the 1/4" diameter
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
over-tighten.
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 shifter tab is
located on the gear-housing end of the winch and operated 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 to the
"IN" position. The winch is now ready for pulling.
9
Ramsey Electric Winches Troubleshooting Guide
Defective solenoid or stuck
solenoid
Jar solenoid to free contacts. Check by applying the appropriate voltage
(12 or 24 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
HOT
Long period of operation Cooling-off periods are essential to prevent overheating
Insufficient battery
Check battery terminal voltage (for each battery) under load. If 10 volts
or less, replace or parallel another battery to it
Bad connection Check battery cables for corrosion; clean and grease
Insufficient charging system Replace with larger capacity charging system
MOTOR RUNS, BUT DRUM
DOES NOT TURN
Clutch not engaged
If clutch engaged but symptom still exists, it will be necessary to
disassemble winch to determine cause and repair
Defective solenoid or stuck
solenoid
Jar solenoid to free contacts. Check solenoid by applying the appropriate
voltage (12 or 24 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
from high pressure car wash
Allow to drain and dry thoroughly, then run motor without load in short
bursts to dry windings.
Clutch not disengaged
Check clutch operation according to nameplate. Make sure clutch shifter
knob is fully at “OUT” position.
Winch not mounted squarely
causing end bearing to bind
drum
Check mounting to see that installation instructions on page 4 have been
followed.
Some or all of the (6) 414861
flat head capscrews attaching
the 479007 ring gear retainer
are too tight
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 criss-cross
pattern, but do not over-tighten. The ring gear must rotate by hand. Reassemble the winch.
MOTOR RUNS IN ONLY ONE
DIRECTION
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER, OR
WITH LOW LINE SPEED
MOTOR WILL NOT OPERATE
CABLE DRUM WILL NOT
FREESPOOL OR IS DIFFICULT
TO FREESPOOL
41
33
11
7
17
25
24
34
14
4
18
24
6
5
21
2
37
3
36
14
10
22
35
20
37
23
32
9
19
26
19
8
31
13
34
12
39
38
7
27
15
16
29
1
28
30
10
REP 8000
Hawse Fairlead
Replacement Kit #251152
Item
No.
Qty. Parts No. Description
Item
No.
Qty. Parts No. Description
1 1 247005 Intermediate Gear Carrier Ass’y 21 6 414861 Capscrew 1/4-20NCx3/4 Lg. Flat Hd. Soc. NYLOK
2 1 247008 Output Gear Carrier Ass’y 22 6 416273 Screw #6-32NCx3/8 Lg. Fil. Hd.
3 1 247024 Input Gear Carrier Ass’y. 23 4 418035 Nut 3/8-16NC Hx. Reg. Z/P
4 1 251110 Switch Ass’y 24 5 418177 Lockwasher 3/8 ID Med. Sect. Plated
5 1 251255 Cable Assembly-95’ 5/16” (8MM) Dia. 25 4 418181 Washer - Flat 3/8 ID S.A.E., Plated
6 1 278158 Solenoid Ass’y 26 1 424023 Clamp
7 1 296553 Brake/Shaft Ass’y 27 1 442207 Gasket
8 1 296589 Motor/End Bearing Ass’y. 28 1 444048 Output Sun Gear
9 1 282062 On/Off Switch Kit 29 1 444097 Input Sun Gear
10 1 332128 Drum - Cable 30 1 448046 Cable Anchor
11 1 334143 Ring Gear 31 2 448049 Tie Bar
12 1 334145 Intermediate Sun Gear 32 1 477002 Locking Ring
13 1 338337 End Bearing 33 1 477013 Cam Ring
14 2 412056 Bushing - Drum 34 2 477004 Ring-Half
15 1 412061 Bushing - Shaft 35 1 479007 Retainer - Ring Gear
16 1 413018 Cover - Gear Housing 36 6 494077 Spring
17 4 414316 Capscrew 3/8-16NCx1-1/4Lg.Hx.Hd.Gr.5,Z/P 37 2 518019 Thrust Washer
18 1 414370 Capscrew 3/8-24NFx1/2 Hx. Hd. Gr. 5 Z/P 38 2 518020 Thrust Washer
19 4 414823 Capscrew 1/4-20NCx3/4 Lg. Soc. Button Hd. 39 1 518027 Thrust Disc
20 1 414830 Capscrew 1/4-20NCx3/8 Lg. Soc. Button Hd. 40 1 289141 Wire Assy - Ground
41 1 452005 Shifter Knob
Roller Fairlead
Replacement Kit #251183
11
REP 9000
34
12
44
45
1
15
3
43
7
20
4
5
26
45
9
45
13
46
14
11
19
25
37
2
21
33
42
29
32
22
31
47
9
19
42
6
41
10
40
23
31
38
24
35
16
18
12V Motor
24V Motor
24
28
28
30
39
31
10
17
27
Item
No.
Qty. Part No. Description
Item
No.
Qty. Part No. Description
1 1 247009 Gear Carrier Ass’y. - Input 23 1 414370 Capscrew 3/8-24NF x 1/2 HX HD ZP GR5
2 1 247022 Gear Carrier Ass’y - Intermediate 24 4 414823 Capscrew 1/4-20NCx3/4 Lg. Soc. Button Hd. (12V)
3 1 247023 Gear Carrier Ass’y - Output 4 414829 Capscrew 1/4-20NCx1 Lg. Soc. Button Hd. (24V)
4 1 251110 Switch Ass’y 25 1 414830 Capscrew 1/4-20NCx3/8 Lg. Soc. Button Hd.
5 1 251255 Cable Assembly - 95' x 5/16" (8mm) Dia. 26 6 414861 Capscrew 1/4-20NCx3/4 Lg. Flat Hd. Soc. NYLOK
6 1 278096 Solenoid Ass’y (24V) 27 1 416212 Screw #10-24NC x 3/8 Lg Hx Soc Hd ZP
1 278158 Solenoid Ass’y (12V) 28 4 418018 Nut 1/4-20NC Hx. Elastic Stop (24V)
7 1 289141 Wire Assy - Ground 29 4 418035 Nut 3/8-16NC Hx. Reg. Z/P
8 1 282062 On/Off Switch Assy (12V) 30 4 418040 Nut 3/8-24NC Hx. Reg. Z/P (24V)
1 282063 On/Off Switch Assy (24V) 31 5 418177 Lockwasher 3/8 Med. Sect. Z/P (12V)
9 1 296181 Brake/Shaft Ass’y (12V) 8 418177 Lockwasher 3/8 Med. Sect. Z/P (24V)
1 296385 Brake/Shaft Ass’y (24V) 32 4 418181 Washer - Flat 3/8 ID S.A.E. Z/P
10 1 296570 Motor (w/End Bearing) (12V) 33 1 424023 Clamp
1 458005 Motor (24V) 34 1 442208 Gasket - Cover
11 1 328138 Cover - Gear Housing 35 1 442219 Gasket
12 1 332193 Drum - Cable 36 1 444077 Gear - Ring, Input
13 1 334147 Gear - Intermediate Sun 37 1 448046 Cable Anchor
14 1 334154 Gear - Input Sun 38 2 448049 Tie Bar
15 1 334197 Gear - Output Sun 39 1 450001 Key (24V)
16 1 334171 Gear - Ring, Output 40 1 477002 Locking Ring
17 1 338282 End Bearing - Motor (24V) 41 1 477013 Cam Ring
18 1 338337 End Bearing - Gear (12V) 42 2 477004 Ring - Half
1 338249 End Bearing - Gear (24V) 43 1 479007 Retainer - Ring Gear
19 2 412056 Bushing - Drum 44 6 494077 Spring
20 1 412061 Bushing - Shaft 45 6 518020 Thrust Washer
21 6 414159 Capscrew 5/16-18NCx2-1/2 Hx Hd Gr.5, Z/P 46 1 518027 Thrust Disc
22 4 414316 Capscrew 3/8-16NCx1-1/4 Hx.Hd.Gr.5,Z/P 47 1 452005 Shifter Knob
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Solenoid Assembly Parts List REP 8000/9000
278158—REP 8000/9000 12V
278096—REP 9000 24V
Note: All unidentified hardware comes
supplied with the solenoid.
Item
No.
Qty.
Req'd
Part No. Description
1 1 289015 Wire Assembly—Battery Red 72"
2 1 289091 Wire Assembly—Red 16 Ga. x 1-1/2” Lg
3 1 289092 Wire Assembly—Black 6 Ga. x 3-1/2” Lg
4 3 289171 Wire Assembly—Black 4 Ga. x 17” Lg. (12v)
3 289115 Wire Assembly—Black 6 Ga. x 17” Lg. (24v)
5 1 289208 Wire Assembly—Black 18 Ga. x 12.5” Lg (12v)
1 289209 Wire Assembly—Black 18 Ga. x 14.5” Lg (24v)
6 2 364002 Strap—Copper
7 1 408102 Bracket
8 1 413024 Cover—Solenoid
9 3 414053 Capscrew 1/4—20NCx1-1/4Lg.Hx.Hd. Z/P
10 7 416216 Screw #10—24NCX 1/2” Lg. Rd. Hd. Z/P
11 2 416227 Screw #10—24NCX 3/4” Lg. Truss Hd. Black
12 6 418004 Nut—Hx. Reg. #10—24NC Z/P
13 6 418014 Nut—Hx. Reg 1/4—20NC Z/P
14 4 418140 Washer #10 SAE Flat Z/P
15 2 418141 Lockwasher #10 Med. Sect. Z/P
16 3 418149 Lockwasher 1/4 Med. Sect. Z/P
17 1 418165 Washer 5/16 Shakeproof External Teeth
18 3 418411 Nutsert #10—24NC
19 3 418514 Spacer
20 1 430013 Connector Female—Molded
21 2 440071 Terminal Tab
22 2 440110 Solenoid—12V
2 440114 Solenoid—24V
23 1 440111 Strap—Copper
24 1 482029 Cover—Female Connector
Limited Lifetime Warranty
Ramsey Winch offers a limited lifetime warranty for each new
Ramsey winch against manufacturing defects in workmanship and
materials on all manufactured components.
Warranty registration cards for each winch must be submitted at the
time of purchase or within 30 days. Warranty will only be valid for
the original purchaser of the winch and installed on the vehicles with
which they were originally registered.
New cable assemblies are warranted against defects in workmanship and materials. No warranty applies after initial use.
All Ramsey mounting kits and other accessories carry a 1-year limited warranty against defects in materials and workmanship.
This warranty is void if winch is used in commercial/industrial applications other than front mount self recovery.
Electrical components consisting of motors, solenoids, wiring, wire
connectors, and associated parts carry a limited 1-year warranty.
Battery isolators carry a 90-day limited warranty.
The obligation under this warranty, statutory or otherwise, is limited
to the replacement or repair at the manufacturers factory, or at a
point designated by the manufacturer, of such part as shall appear
to the manufacturer, upon inspection of such part, to have been
defective in material or workmanship. This Warranty does not obligate Ramsey Winch Company to bear the cost of labor or
transportation charges in connection with the replacement or repair
of defective parts, nor shall it apply to a product upon which repairs
or alterations have been made, unless authorized by the manufacturer, or for equipment misused, neglected or improperly installed.
Impor
tant notice: To the fullest extent permitted by applicable
law, the following are hereby excluded and disclaimed: 1. All
warranties of fitness for a particular purpose; 2. All warranties of merchantability; 3. All claims for consequential or
incidental damages. There are no warranties that extend
beyond the description that appears on the face hereof.
Some states do not allow the above exclusions or disclaimers
in consumer transactions and as such this disclaimer/exclusion may not apply to your particular case.
To the extent such warranties of fitness for a particular purpose or merchantability are deemed to apply to this product,
they exist only for so long as the express limited warranty
elsewhere set forth is in existence.
Ramsey Winch Company makes no warranty in respect to accessories, same being subject to the warranties of their respective
manufacturers.
Ramsey Winch Company, whose policy is one of continuous product improvement, reserves the right to improve any product through
changes in design or materials as it may deem desirable without
being obligated to incorporate such changes in products of previous
manufacture.
If field service at the request of the buyer is rendered and the fault is
found not to be with Ramsey Winch Company’s product, the buyer
shall pay the time and expense of the field representative. Bills for
service, labor or other expenses which have been incurred by the
buyer without express approval or authorization by Ramsey Winch
Company will not be accepted.
This warranty gives you specific legal rights and you may also have
other legal rights which vary from state to state.
Warranty Information
Ramsey Winches are designed and built to exacting specifications. 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.
13
14
Félicitations!
Vous venez de vous procurer le meilleur treuil dans sa catégorie! Il
présente un train planétaire à trois étages extrêmement efficace qui
transmet son couple par l'entremise d'un moteur à courant continu
(c.c.) à enroulement série. Leur embrayage direct sécuritaire permet
le décrabotage, ce qui accélère le déploiement du câble. Ils sont en
outre équipés d'un frein à correction automatique de charge conçu
pour supporter la pleine capacité nominale du treuil.
Ces treuils ont été dessinés et fabriqués de manière à être le plus
utiles possible. Mais comme tous les dispositifs qui allient puissance et mouvement, ils présentent certains dangers si on ne les
utilise pas correctement. En prenant d'abord toutes les précautions
requises, on élimine non seulement ces dangers, mais on facilite et
on accélère les tâches à effectuer.
Veuillez donc prendre la peine de lire le présent guide attentivement;
il contient des renseignements utiles pour tirer le meilleur parti de
votre treuil Ramsey, de même que des consignes de sécurité qu'il
vous faut savoir avant de l'utiliser pour la première fois. En observant notre mode d'emploi, vous garantirez que votre treuil vous offre
des années de satisfaction. Nous vous remercions d'avoir choisi
Ramsey; nous sommes convaincus que vous ne le regretterez pas!
Remarque: les treuils REP 8000 et 9000 sont conçus pour être
fixés à l'avant d'un véhicule. Ils ne conviennent pas aux applications
commerciales ou industrielles (remorqueuses, porte-voitures,
dépanneuses, opérations de levage, etc.) et Ramsey n'en garantit
pas le fonctionnement dans de telles conditions; la société offre des
gammes complètes et distinctes de treuils réservés à ces usages.
Prière de communiquer avec l'usine pour obtenir de plus amples
renseignements à ce sujet.
Ramsey Winch Company
Guide de l’utilisateur
Treuil électrique avant
Table des matières
Consignes de sécurité ........................................16
Conseils de sécurité ............................................16
Trucs et techniques ............................................17
Installation ....................................................18-21
Fonctionnement et câblage électrique ..................19
Maintenance........................................................22
Mode d'emploi ....................................................22
Diagnostic des anomalies....................................23
Liste des pièces ............................................24-26
Garantie ..............................................................27
MISE EN GARDE : on doit lire et comprendre le présent guide avant de procéder à l'installation et à l'utilisation
du treuil. Se reporter à la section Consignes de sécurité.
Model REP 8000 12 volt
Model REP 9000 12 and 24 volt
REP 8000 CE
Couche(s) de câble 1234
(lbs) 8,000 6,500 5,500 4,800
(kg) 3,620 2,940 2,490 2,170
(ft) 15 40 70 95
(m) 4 12 21 28
(lbs) 0 2,000 4,000 6,000 8,000
(kg) 0 900 1,810 2,720 3,620
(FPM)
36 15 12 8 5
(MPM)
10.9 4.5 3.6 2.4 1.5
Courant tiré 87 168 258 320 405
REP 9000 CE
Couche(s) de câble 12345
(lbs) 9,000 7,300 6,200 5,400 4,700
(kg) 4,070 3,300 2,800 2,440 2,130
(ft) 15 35 60 90 105
(m) 4 10 18 27 32
(lbs) 0 2,000 4,000 6,000 9,000
(kg) 0 900 1,810 2,720 4,070
(FPM) 12V
33 17 13 11 8
24V 25 15 11 9 7
12V
10 5.1 3.9 3.3 2.4
(MPM)
24V 7.6 4.5 3.3 2.7 2.1
12V
97 180 260 335 420
24V 35 75 110 140 175
* À condition que le câble soit uniformément distribué sur l'enrouleur.
Courant tiré
Capacité de traction nominale
par couche
Capacité de traction cumulative
par couche*
5/16" (8mm) dia.
Vitesse de traction, première
couche
Capacité de traction nominale
par couche
Capacité de traction, première
couche
Capacité de traction, première
couche
Vitesse de traction, première
couche
Capacité de traction cumulative
par couche*
5/16" (8mm) dia.
French
15
16
Consignes de sécurité
Le câble doit faire au moins cinq tours sur l'enrouleur pour pouvoir
soutenir la charge nominale du treuil, ce que le serre-câble est incapable de faire.
A. L'utilisateur ainsi que toute autre personne doivent se tenir à une
distance latérale sécuritaire du câble lorsque celui-ci tire une
charge.
B. On ne doit pas tenter d'enjamber le câble ou de marcher près de
ce dernier quand il tire une charge.
C. On doit se servir de la sangle fournie lorsqu'on manipule le cro-
chet pour enrouler un câble métallique.
D. On ne doit pas déplacer le véhicule pour tirer sur une longue dis-
tance une charge accrochée au câble, ce qui pourrait causer le
bris de ce dernier.
E. On doit avoir recours à des gants ou à un chiffon épais pour se
protéger des barbures quand on manipule le câble.
F. On doit bloquer les roues du véhicule quand celui-ci est sur une
pente.
G. L'embrayage du treuil doit être désaccouplé quand ce dernier
n'est pas utilisé, et complètement accouplé quand il l'est.
H. Les modifications, changements ou déviations apportés à ces
treuils doivent être confiés à la Ramsey Winch Company.
I. On doit réduire au minimum la durée de chaque traction. Si le
moteur devient inconfortablement chaud au toucher, on doit l'arrêter et le laisser refroidir pendant quelques minutes. Les charges
nominales ou presque nominales ne doivent pas être tirées plus
de une minute. Couper l'alimentation du treuil si le moteur cale.
Ces treuils électriques sont conçus pour un usage intermittent et
ne doivent pas être utilisés en applications de service constant.
J. On doit déconnecter la télécommande du treuil quand celui-ci
n'est pas utilisé.
K. Remarque: on ne doit pas se servir de ces treuils en applica-
tions de levage puisqu'ils ne répondent pas aux exigences de ces
dernières en matière de caractéristiques et de sécurité.
L. On ne doit pas dépasser les capacités de traction nominales
apparaissant aux tableaux du présent guide; les surcharges d'impact doivent rester en dessous des valeurs qui y sont indiquées.
M. Pour réenrouler correctement le câble, il est nécessaire de lui
appliquer une certaine charge. Pour ce faire, on doit tenir le câble
d'une main (gantée) et la télécommande de l'autre, en commençant le plus loin et le plus au centre possible et en marchant
vers le véhicule en maintenant la tension sur le câble pendant
que le treuil fait son travail. Prendre soin de ne pas laisser glisser
le câble de sa main et ne pas trop s'approcher du treuil. Arrêter
ce dernier et reprendre la procédure jusqu'à ce qu'il ne reste plus
qu'environ un mètre de câble à réenrouler. Déconnecter la télé-
commande et terminer la procédure en faisant tourner l'enrouleur
manuellement (embrayage désaccouplé). En présence de treuils
cachés, réenrouler le câble mécaniquement, en utilisant la sangle
de crochet fournie.
Conseils de sécurité
Il ne faut jamais sous-estimer les risques potentiels associés à l'utilisation d'un treuil, mais il ne faut pas non plus les craindre outre
mesure. Il s'agit de connaître les dangers principaux et de tout faire
pour les éviter.
Le fait que le câble ne s'enroule pas uniformément lorsqu'il tire une
charge ne pose pas de problème, à moins qu'il ne s'accumule d'un
seul côté de l'enrouleur. Le cas échéant, mettre le treuil en marche
arrière de manière à réduire la charge, puis déplacer le point d'ancrage plus au centre du véhicule. Une fois le travail terminé, il suffit
de dérouler le câble pour le réenrouler ensuite de manière plus
égale.
On recommande de ranger la télécommande à l'intérieur du véhicule
afin de la protéger d'éventuels dommages, et de l'inspecter avec de
la brancher.
Lorsqu'on est prêt à procéder à l'enroulement, on doit débrayer pour
brancher la télécommande; l'embrayage ne doit jamais être accouplé
pendant que le moteur est en marche.
On ne doit jamais amarrer le crochet au câble, ce qui pourrait
endommager ce dernier. Il faut plutôt employer une bretelle ou une
chaîne assez forte, tel qu'illustré.
Dans la mesure du possible, on doit garder l'œil sur le treuil pendant
qu'il fonctionne (tout en se tenant à une distance respectable). Si on
utilise la force motrice du véhicule pour aider à tirer, il faut sortir à
chaque mètre parcouru pour s'assurer que le câble ne s'accumule
pas d'un côté de l'enrouleur. Un blocage de câble peut provoquer le
bris du treuil.
Ne pas fixer de crochet de remorquage aux dispositifs de fixation du
treuil (le crochet doit plutôt être assujetti au châssis du véhicule).
Lorsqu'on utilise deux câbles en situation de treuillage stationnaire,
le crochet devrait également être assujetti au châssis du véhicule.
Étant donné que c'est la couche la plus près de l'enrouleur qui produit la plus grande force de traction, il est préférable de sortir autant
de câble que possible lorsqu'on veux tirer une charge plus lourde
(en se rappelant cependant qu'il faut laisser au moins cinq enroulements sur l'enrouleur). S'il est impossible de procéder ainsi, on peut
utiliser une moufle mobile et deux câbles (voir illustration).
En enroulant le câble de manière uniforme et serrée, on évite les
blocages engendrés par les coincements entre deux câbles. Si cela
se produit, il suffit de faire avancer et reculer le treuil de quelques
pouces à la fois. Il ne faut jamais tenter de dégager mécaniquement
un câble bloqué lorsqu'il est chargé; le cas échéant, procéder
manuellement.
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