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TABLE OF CONTENTS
INTRODUCTIONS............................................................................................................... 1
WARRANTY INFORMATION...............................................................................................1
SPECIFICATIONS................................................................................................................1
WARNINGS..........................................................................................................................1
CABLE INSTALLATION.......................................................................................................2
ROLLER GUIDE INSTALLATION........................................................................................ 2
HYDRAULIC SYSTEM REQUIREMENTS........................................................................... 3
PERFORMANCE CHARTS..................................................................................................3
OPERATION........................................................................................................................4
MANUAL REMOTE CLUTCH SHIFTER.............................................................................. 4
MAINTENANCE.................................................................................................................. 4
TROUBLE SHOOTING GUIDE............................................................................................5
BRAKE ADJUSTMENT........................................................................................................6
INSTRUCTIONS FOR OVERHAUL................................................................................. 7-12
DIMENSIONAL DRAWING................................................................................................. 13
PARTS LIST AND PARTS DRAWINGS........................................................................ 14-15
LIMITED WARRANTY........................................................................................................ 16
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RAMSEY HYDRAULIC PLANETARY WINCH MODEL RPH-8000-Y
PLEASE READ THIS MANUAL CAREFULLY
This manual contains useful ideas in obtaining the most efficient operation from your Ramsey Winch, and
safety procedures one needs to know before operating a Ramsey Winch. Do not operate this winch until you
have carefully read and understand the "WARNING" and "OPERATION" sections of this manual.
WARRANTY INFORMATION
Ramsey Winches are designed and built to exacting specifications. Great care and skill go 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 our winch, please follow instructions for prompt service on
all warranty claims. Refer to back page for limited warranty.
SPECIFICATIONS*
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.
WARNINGS:
CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCH.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
DO NOT LEAVE A LOAD ON THE WINCH DURING TRANSIT.
DO NOT LEAVE CLUTCH ENGAGED WHEN WINCH IS NOT IN USE.
STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS.
STAND CLEAR OF CABLE WHILE PULLING. DO NOT TRY TO GUIDE CABLE.
DO NOT EXCEED MAXIMUM LINE PULL RATINGS SHOWN IN TABLE.
DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PERSONNEL.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE
LOAD. CABLE CLAMP (SETSCREW) IS NOT DESIGNED TO HOLD LOAD.
WHEN PULLING A HEAVY LOAD PLACE A BLANKET, JACKET, OR TARPAULIN OVER THE CABLE
FIVE OR SIX FEET FROM THE HOOK.
AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR, AS THEY MAY INDICATE A
DANGEROUS SITUATION.
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CABLE INSTALLATION
A decal on the top of the end bearing indicates the spooling direction of the cable. Another decal
(located on brake housing) indicates the balls in the brake are in #1 slots. If the decals are
damaged or unreadable, contact Customer Service for additional instructions to determine proper
direction.
1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of cable,
opposite hook, with plastic or similar tape to prevent fraying.
2. Place taped end of cable into hole in cable drum, as shown below. Use 3/8-16NC x 1/2 lg. Hx.
Soc. drive setscrew to secure cable to drum.
3. Carefully run winch in the "reel-in" direction. Keeping tension on end of cable, spool all the cable
onto the cable drum, taking care to form neatly wrapped layers.
After installing cable, check freespool operation. Disengage clutch and pull on cable at a walking
speed. If cable "Birdnests", loosen jam nut (item #28) and turn nylon screw (item #23) clockwise to
increase drag on drum. If cable pull is excessive loosen nylon setscrew by turning
counterclockwise. Tighten jam nut when proper setting is obtained. CAUTION: Over-tightening of
jam nut may strip nylon setscrew.
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HYDRAULIC SYSTEM REQUIREMENTS
Refer to the performance charts below to properly match your hydraulic system to the winch performance.
The charts consist of: (1) line pull (LB) first layer vs. working pressure (PSI) and (2) line speed, first layer
(FPM) vs. flow (GPM). STATIC (solid line) refers to hoisting a suspended load from rest; DYNAMIC (dotted
line) refers to maintaining the motion of a moving load. A cylinder spool directional control valve is
recommended.
SYSTEM REQUIREMENTS:
2500 PSI RELIEF VALVE SETTING
15 GPM FLOW RATE*
10 MICRON NOMINAL FILTRATION
1000 PSI MAXIMUM BACK PRESSURE
*CAUTION:
DO NOT EXCEED 20 GPM. IF EXCEEDED, MOTOR AND WINCH MAY BE DAMAGED.
PERFORMANCE CHARTS
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OPERATION
The best way to get acquainted with how your winch operates is to make test runs before you actually use
it. Plan your test in advance. Remember, you hear your winch, as well as see it operate. Get to recognize
the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Avoid
conditions where load shifts or jerks occur, as they may indicate a dangerous situation.
The uneven spooling of cable, while pulling a load, is not a problem, unless there is a 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.
When pulling a heavy load place a blanket, jacket or tarpaulin over the cable about five or six feet behind the
hook. In the event of a broken cable, this will slow the snap back of the cable and could prevent serious
injury.
The winch clutch allows rapid unspooling of the cable, from cable drum, for hooking onto the load. The clutch
is operated by the clutch shifter lever.
MANUAL REMOTE CLUTCH SHIFTER
TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the cable. Lift up
knob and pull out, lock in place. With knob in the "DISENGAGED" position cable may now be free-spooled
from drum. SEE WARNING LABEL LOCATED BY SHIFTER KNOB.
TO ENGAGE CLUTCH:
Run the winch in reverse until the clutch knob snaps fully into the "ENGAGED" position. DO NOT attempt to
pull a load unless the handle is fully at the "ENGAGED" position.
WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD.
(Refer to page 13)
Lift up knob then release. SEE WARNING LABEL LOCATED BY SHIFTER KNOB.
MAINTENANCE
1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with broken strands, re-
place immediately. Cable and hook assembly (100' lg. cable) P/N 524118 ("Y" drum) may be purchased
from a Ramsey distributor.
2. Check that the clutch is fully engaging. See OPERATION instructions above. Monthly disengage clutch,
put several drops of oil on the shaft and work clutch IN and OUT several times to lubricate inside of clutch
cylinder.
3. Check brake for drift. Refer to page 6.
4. Check oil level of winch brake housing every month. Remove oil level plug (refer to pg.12). Oil level
should be kept up to oil level hole (plus or minus 1/8"). Replace oil annually or more often if winch is used
frequently. Use 1/2 pint of Mobilfluid 424, Phillips HG Fluid, Texaco TDH, Shell Oil Co. Donax TD high performance tractor transmission fluid or equivalent, and for quietest operation, add 1/4 fl. oz. of an oil additive
(available from the factory).
5. Check to see that drum cable does not overrun (BIRDNEST) when freespooling. Refer to page 2.
6.
Replace drum bushings and seals when seals begin to seep grease. Refer to OVERHAUL INSTRUCTIONS, page 7. Add additional lubricant, Mobilith SHC 007, to gears if required.
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TROUBLE SHOOTING GUIDE
CONDITIONS POSSIBLE CAUSE CORRECTION
DRUM WILL NOT ROTATE Brake damaged. Inspect and replace brake.
AT NO LOAD
Gears damaged. Inspect and replace damaged gears.
DRUM WILL NOT ROTATE Load greater than rated Refer to Specifications pg.1
UNDER LOAD capacity of winch. for line pull rating.
Low hydraulic system Check pressure. Refer to HYDRAULIC
pressure. SYSTEMS performance charts pg. 3.
WINCH RUNS TOO SLOW Low hydraulic system flow rate. Check flow rate. Refer to
HYDRAULIC SYSTEMS flow chart page 3.
Motor worn out. Replace motor.
DRUM WILL NOT Clutch not disengaged. Check OPERATION. Refer to page 4.
FREESPOOL Check ADJUSTMENT. Refer to page 11.
Side-mount bolts (item #19, Check bolt length. Bolt thread MUST NOT
Page 15) too long causing engage threaded holes in sides of end
binding of ring gear. bearing by more than the .50 inch thread
depth in the end bearing. Refer to
CAUTION on pg.12
OIL LEAKAGE Damaged brake housing Replace gasket. Check for plugged
gasket or breather. breather. Refer to pgs. 7 & 9.
Damaged brake hub seal. Replace seal. Refer to pg. 9.
OIL LEAKAGE FROM Breather below oil level. Check oil level.
BREATHER PLUG
LOAD DRIFTS Brake needs adjusting. Adjust brake. Refer to pg. 6.
CABLE BIRDNESTS WHEN Drag screw improperly Adjust nylon drag screw.
CLUTCH IS DISENGAGED adjusted. Refer to pg. 2.
EXCESSIVE NOISE Brake torque too high. Reduce torque. Refer to page 6.
Hydraulic system flow too high Check flow rate. Refer to HYDRAULIC
SYSTEMS flow chart pg. 3.
Brake oil level low. Check oil level, add oil if necessary.
DRUM CHATTERS, Low hydraulic system flow. Check flow rate. Refer to HYDRAULIC
in "REEL IN" direction SYSTEMS flow chart pg. 3.
Low hydraulic system Check relief valve setting. Refer to
relief pressure setting. HYDRAULIC SYSTEMS pg. 3.
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ADJUSTING THE BRAKE
All parts of the oil-cooled automatic safety brake are bathed in oil. When the brake wears
to the point that the load begins to drift, the brake can be adjusted as follows:
1. Loosen the lock nut on the adjusting screw (see drawing on page 9).
2. Increase the brake torque by turning the adjusting screw clockwise. CAUTION: Only
1/4 turn is usually required to adjust the brake. Over-tightening can cause overheating, and damage to the brake parts. Tighten the lock nut after adjustment is
completed.
If the brake does not respond to adjustment, then a new flat spring (item #4) and/or brake
discs (item #33) may be needed.
Brake torque can be checked/set as follows: A torque wrench can be equipped with a
special adapter to fit the input coupling of the winch. The adapter can be made by welding
a 1" dia. straight motor shaft, with 1/4" key, in a 1" hex. socket, as shown in the following
figure.
This special adapter will fit into the motor shaft coupling. Place coupling onto drum
shaft in winch. Turn the torque wrench so that the drum turns in the "CABLE OUT"
direction (lowering direction). The torque setting for the brake should be 155 to 160 ft.
lbs. If the torque wrench does not show the proper torque value, the adjusting screw
should be adjusted 1/4 turn (clockwise if torque is low or counter-clockwise if torque is
high). Each time the adjusting bolt is turned, check the torque reading. Continue this
procedure until the proper torque reading is achieved. Then tighten the lock nut. If
proper adjustment cannot be made, follow overhaul instructions on page 9.
After the brake has been adjusted to the proper torque setting, as described above,
disengage clutch. Start vehicle engine and run winch in the "CABLE IN" (raise
direction). Allow winch to run in this direction for one minute.
Place your hand on the brake housing. If housing is not hot to the touch then run winch
in the reverse direction (cable out) for one minute. Brake housing should begin to heat.
When these conditions exist, proper installation has been made. If heating becomes
noticeable when running the winch in "CABLE IN" (raising direction), the brake should be
again disassembled. When disassembled, place the brake balls in the alternate set of
slots in the cam plate (see View A-A page 9), then carefully follow the instructions for
re-assembling and checking the brake.
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INSTRUCTIONS FOR OVERHAUL OF RAMSEY WINCH MODEL RPH-8000-Y
DISASSEMBLY
Remove frame assembly (item #2) by unscrewing (8) capscrews (item #19). Remove breather plug
and reducer (item #35 & #40) from winch. Drain oil from winch by removing plug (item #41).
Remove motor (item #36), coupling (item #32) from winch by unscrewing capscrews (item #25). If
coupling is being replaced, be sure pin (item 42) is installed. Tap motor lightly to disengage.
Replace all o-rings and seals with new ones during re-assembly (order kit #246042). If necessary,
remove valve (item #50) from motor by removing capscrews (item #22) and lockwashers (item #53).
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Remove tie plates (item #14) from end bearings (items #8 & #9) by unscrewing
capscrews (item #19), as shown. Slide motor end bearing (item #8) from drum (item #1)
and drum from gear housing end bearing (item #9). Remove input shaft (item #13) from
end bearing. Inspect teeth of gear (item #6) for signs of wear. If necessary replace gear
by removing snap ring (item #48) and thrust washer (item #51). Slide new gear over
splines of shaft and against snap ring on shaft. Re-install thrust washer and place snap
ring into groove of shaft.
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Remove brake housing (item #10) from end bearing (item #9) by unscrewing (4) capscrews (item #24). Remove
gasket (item #34), coil spring (item #49), flat spring (item #4), retainer plate (item #12), composition brake discs
(item #33), and cam plate (item #5). Remove hub (item #11) with plug (item #43)--which is press-fitted in the
hub I.D. Inspect the seal (item #38) inside of gear housing bore, and replace if necessary.
Inspect brake discs. Discs are 1/4” thick when new, replace if thinner than .200 in. thick or if surfaces are glazed or
burnt. Inspect the flat ground surfaces of the cam plate and retainer place the glazing, warpage, or other damage.
Glazing can be removed by scraping carefully. Inspect flat spring. It should be bowed at least 1/8”. Replace spring if
bowed less than 1/8”.
Replace all worn or damaged parts as needed. Reassemble all parts as shown. Be sure balls are secure between
cam plate and hub.
Install brake housing making sure that ends of capscrews (item #18) go through notches in end of flat spring and
holes in retainer plate. Secure brake housing to end bearing using capscrews (item #24). Tighten capscrews to 3040 ft-lbs.
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Remove o-ring (item #37) and bushing (item #16) from motor end bearing (item #8).
Press new bushing onto end bearing and dip o-ring in oil and seat into groove of end
bearing. Remove seal (item #46) from gear housing end bearing (item #9). Loosen nut
(item #28) and remove nylon setscrew (item #23) and remove ring gear (item #7) from
gear housing end bearing, if necessary. Remove bushing (item #18) from gear housing
end bearing (item #9). Press new bushing (item #18) into place in end bearing. Install
ring gear and nylon setscrew and nut. Ring gear must be fully seated in gear housing end
bearing (item #9) and slot in ring gear must NOT be aligned with clutch shifter hole. Install
new seal in gear housing end bearing, with sharp edge of seal outward.
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Generously apply grease (MOBILITH SHC 007) to teeth of ring gear (item #7), teeth of planet gears in drum
(item #1) and to bushing in end bearings (item #8 & #9). Apply grease to teeth of gear (item #6) and to
splines of shaft (item #13). Place splined end of shaft into splines of hub in brake housing end bearing (item
#9). Place drum over shaft and rotate drum to engage planet gears with output gear on shaft and ring gear
in end bearing.
Assemble end bearing to drum assembly and use tie plates (item #14) and capscrews (item #19) to hold
both end bearings together. Tighten capscrews to 55 Ft. Lbs. (75 Nm.).
MANUAL REMOTE CLUTCH SHIFTER ADAPTER ASSEMBLY
Remove by loosening setscrew (item #26), jam nut and unscrewing clutch shifter. Be sure slot in ring gear
is not aligned with clutch shifter hole. Rotate drum, if necessary, to insure hole and slot are not aligned.
Reinstall clutch shifter with plunger, jam nut and rod adapter positioned in cylinder housing, as shown.
Thread assembly (with rod adapter engaged in cylinder slot) into the end bearing. Pull drum toward the
brake housing end bearing to remove play. Hold drum in the position and continue threading the shifter
assembly in until the gap between the end of the handle and cylinder is 7/16 +
will vary with drum endplay. With the drum pulled against the gear housing, the gap should be 7/16 inch.
Lightly tighten jam nut. Rotate drum until rod adapter snaps fully into the engaged position.
Disengage clutch and verify that drum can be rotated freely (at least one full revolution) with clutch shifter at
DISENGEGED position. Securely tighten jam nut. Tighten setscrew securely. Re-check clutch operation
as described on page 4.
1/32 inch. NOTE: This gap
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Before installing motor, check brake adjustment (refer to page 6, ADJUSTING THE
BRAKE).
Place splined end of coupling (item #32), with spirol pin (item #42) installed, inside of
motor end bearing housing (item #8) and slide over splines on end of input shaft. Place
o-ring (item #39) around motor pilot. Mount motor (item #36) to end bearing by aligning
key on motor shaft with keyway in coupling. Be sure that motor mounts flush to end bearing and that o-ring is set securely in place between motor and end bearing. Secure motor
to end bearing using two capscrews and lockwashers (items #25 & #31). Tighten capscrews to 49 Ft.Lbs. (66 Nm). Thread plug (item #41) into bottom of brake housing.
Permatex can be added to threads of plug to help in sealing. Pour a mixture of 8 oz. of
Mobilfluid 424, Phillips HG Fluid, Texaco TDH, Shell Oil Co. Donax TD high performance
tractor transmission fluid, or equivalent and 1/4 oz. of an additive (available from the factory), into oil level hole. Oil level should be kept at oil level hole (plus or minus 1/8").
Thread plug (item #41) into oil level hole. Insert reducer (item #40) into hole in top of
brake housing and breather plug (item #35) into reducer. Tighten plugs and reducer
securely. Attach frame assembly (item #2) to winch using (8) capscrews (item #19).
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PARTS LIST RPH-8000-Y WITH REMOTE MANUAL CLUTCH SHIFTER ADAPTER
ITEM# QTY. PART NO. DESCRIPTION
1 1 234165 DRUM ASS'Y. -"Y"
2 1 242154 FRAME ASSEMBLY
3 1 276054 SHIFTER ASS'Y.
4 1 306035 SPRING-FLAT, BRK.
5 1 314017 CAM PLATE-BRAKE "A" ROTATION
6 1 334174 GEAR-OUTPUT, SUN
7 1 444084 GEAR-RING
8 1 338326 END BEARING-MOTOR
9 1 338327 HOUSING-GEAR, END BEARING
10 1 338328 HOUSING-BRAKE
11 1 314019 HUB-PLATE
12 1 352021 RETAINER PLATE
13 1 357489 SHAFT-INPUT "Y"
14 2 474080 TIE PLATE "Y"
15 3 400007 BALL
16 1 412084 BUSHING-DRUM, MOTOR END
17 1 412085 BUSHING-DRUM, GEAR
18 2 414273 BOLT-3/8-16NC X 1-3/4, HX, GR. 5
19 16 414581 CAPSCREW-1/2-13NC X 3/4 LG. HX. HD., GR. 5, Z/P
20 1 414622 BOLT-1/2-13NC X 2-1/4, HX. HD., GR. 5, ALL-THD.
21 2 414836 CAPSCREW-1/4-20NC X 1/2, HX. SOC. HD.
22 4 414159 CAPSCREW-5/16-18NC X 2-1/2, HX. HD., GR. 5, Z/P
23 1 414926 SETSCREW-3/8-16NC X 1, SOCKET, NYLON
24 4 414934 CAPSCREW-3/8-16NC X 2-3/4, HX. SOC. HD.
25 2 414952 CAPSCREW-1/2-13NC X 1-1/2, SOC. HD.
26 1 416016 SETSCREW-1/4-20NC X 1/4 HX. SOC. HD.
27 4 418034 NUT 3/8-16NC HEX. REG.
28 1 418036 NUT 3/8-16NC HEX. JAM
29 1 418061 NUT-1/2-13NC HEX. JAM
30 4 418184 WASHER-3/8 ID X 5/8 OD X 1/16 FLAT ALUM
31 2 418218 LOCKWASHER-1/2 ID MED. SECT.
32 1 431014 COUPLING-HYD. MOTOR
33 2 438018 PLATE-BRAKE
34 1 442212 GASKET-BRK. HSG.
35 1 456008 RELIEF FITTING
36 1 458074 MOTOR-HYD.
37 1 462046 O-RING
38 2 462047 QUAD-RING
39 1 462048 O-RING
40 1 468002 REDUCER
41 2 468018 PIPE PLUG
42 1 470033 SPIROL PIN
43 1 472051 PLUG
44 1 472052 PLUG
45 1 486076 SEAL
46 1 486080 SEAL-GEAR HSG.
47 1 518037 SHIM
48 2 490003 SNAP RING
49 1 494010 SPRING
50 1 516008 VALVE-COUNTERBALANCE ("A" ROTATION)
51 1 518047 WASHER-THRUST
52 1 340077 BRAKE SHAFT
53 4 418163 LOCKWASHER - 5/16 MED SECT Z/P
Effective Serial Number: 2038147
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MODEL RPH 8000-Y
WITH REMOTE MANUAL CLUTCH SHIFTER ADAPTER
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NOTES
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NOTES
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OM-914010-1104-H
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