Ramsey Winch REP 8000 Le manuel du propriétaire

Marque: Ramsey Winch

Modèle: REP 8000

Taper: Le manuel du propriétaire

Ce manuel convient également à

REP 9000

Owner’s Manual

Front Mount Electric Winch

12 & 24 volt

REP 8000

REP 9000

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-914118-0106-F

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 improp-

erly 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 begin-

ning 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, com-

plete 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.

Rated Line Pull Per Layer

Line Pull First Layer

Line Speed First Layer

Cumulative Cable Cap. Per

Layer*

5/16" (8mm) dia. Cable

Amp Draw

Rated Line Pull Per Layer

Cumulative Cable Cap. Per

Layer*

5/16" (8mm) dia. Cable

Line Speed First Layer

(MPM)

English

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 opera-

tions. 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 stand-

ing 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.

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 vehi-

cle hood for additional protection.

Use the vehicle wheel power to help the winch, but don't over-

take 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.

Installation

The winches shown in this owner's manual are solely and exclu-

sively 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 recommend-

ed 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 bot-

tom 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 sur-

face 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

View A-A

REP 9000 12V

REP 8000

FIGURE 3

Hole for Solenoid

Ground Wire Bolt

View A-A

REP 9000 24V

FIGURE 4

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 wash-

ers) 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, sup-

plied 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 BAT-

TERY 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 bat-

tery 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 direc-

tions. 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.

FIGURE 5

TO ENSURE PROPER ALIGNMENT

OF THE ROLLER FAIRLEAD TO THE

DRUM, POSITION SMALLER (7/16") SET

OF HOLES AT 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.

FIGURE 7

FIGURE 9

FIGURE 8

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 assem-

bly 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 tem-

porarily and confirm that the cable spools when the shifter is

in the Engaged position.

FIGURE 10

FIGURE 11

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 fray-

ing. 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" direc-

tion 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 con-

stant. 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.

Ramsey Electric Winches Troubleshooting Guide

CONDITION POSSIBLE CAUSE CORRECTION

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. Re-assemble 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

REP 8000

Hawse Fairlead

Replacement Kit #251152

REP 8000 PARTS LIST

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 477003 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

Roller Fairlead

Replacement Kit #251183

REP 9000

24V Motor

12V Motor

REP 9000 PARTS LIST

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 334170 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 477003 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

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 workman-

ship and materials. No warranty applies after initial use.

All Ramsey mounting kits and other accessories carry a 1-year lim-

ited warranty against defects in materials and workmanship.

This warranty is void if winch is used in commercial/industrial appli-

cations 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 obli-

gate 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 manufactur-

er, 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 war-

ranties 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/exclu-

sion may not apply to your particular case.

To the extent such warranties of fitness for a particular pur-

pose 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 acces-

sories, same being subject to the warranties of their respective

manufacturers.

Ramsey Winch Company, whose policy is one of continuous prod-

uct 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 warran-

ty 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.

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 puis-

sance 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 obser-

vant 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.

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.

Courant tiré

Capacité de traction nominale

par couche

Capacité de traction cumulative

par couche*

5/16" (8mm) dia.

Vitesse de traction, première

couche

French

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 inca-

pable 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'ar-

rêter 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'im-

pact 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 com-

mençant 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'utili-

sation 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'an-

crage 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 pro-

duit 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 enroule-

ments 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.

Trucs et techniques

La meilleure façon de connaître le fonctionnement d'un treuil est de

procéder à quelques essais avant d'en avoir réellement besoin. Ces

essais doivent être planifiés à l'avance. Avec le temps, on arrive à

distinguer le son d'une traction légère et uniforme de celui d'un effort

soutenu ou d'une procédure irrégulière où la charge avance par à-

coups ou se déplace latéralement. On prend ainsi toute l'assurance

requise pour utiliser le treuil presque d'instinct.

Un treuil peut non seulement tirer un véhicule en haut d'une pente ou

l'aider à la descendre, mais aussi permettre d'en remorquer un autre

ou encore une charge si le véhicule est ancré en position station-

naire. Les scénarios suivants illustrent certaines techniques à

adopter.

Lorsqu'on veut tirer une charge importante, il faut mettre une cou-

verture, un manteau ou une bâche sur le câble sur les deux

premiers mètres à partir du crochet et ce, afin de ralentir d'éventuels

retours si le câble se brise. Il faut également ouvrir le capot du

véhicule pour plus de protection.

On peut se servir d'une force motrice pour assister le treuil, mais il

faut s'assurer que le câble ne passe pas sous le véhicule. La procé-

dure doit être bien planifiée. On peut accrocher la charge et la tirer

en une seule opération. Pour ce faire, il faut bien examiner les points

d'ancrage possibles, de même que les situations, les directions et

les objectifs de traction.

Les treuils munis de fils guide-câble peuvent tirer des

charges de plusieurs directions. On ne doit cependant tirer

en angle que pour rétablir le véhicule, au risque d'endom-

mager les éléments structurels ou d'autres pièces de ce

dernier ou encore d'engendrer une accumulation de câble

d'un côté de l'enrouleur.

Pour tirer un véhicule d'une simple mauvaise posture, ancrer le

câble à un arbre (se servir alors d'un protecteur de tronc) ou à

une pierre lourde.

Une série de piquets plantés dans un sol compact et reliés

par une chaîne peut constituer un bon point d'ancrage en

cas d'autorétablissement simple, quand le câble ne peut être

fixé à aucun élément naturel.

Pour tirer directement une charge pouvant aller jusqu'à

900 kg, accrocher le véhicule à un point d'ancrage solide

(un arbre, par exemple) et le mettre au neutre.

Pour obtenir un point d'ancrage solide, enterrer partielle-

ment un billot dans de la terre ou du sable, ou le mettre

dans un fossé profond.

To double the pull, use 2-part line with snatch block and

tie off to chassis. Take out of gear.

Installation

Les treuils décrits dans le présent guide sont exclusivement conçus

pour une installation à l'avant d'un véhicule et pour des applications non

industrielles ou commerciales. Tout autre emploi en annulerait la

garantie.

Remarque: en présence d’un protège-calandre, la manette de com-

mande pourrait devoir être déplacée. Se reporter alors aux pages 7 et 8

pour savoir comment procéder.

Il est très important de fixer le treuil à une surface plane, de manière à

ce que ses trois sections principales (le moteur, l'enrouleur et l'en-

grenage) soient bien alignées. On recommande d'utiliser une trousse

Ramsey pour procéder à l'installation; ces trousses sont conçues pour

aligner le treuil, en distribuant la charge nominale uniformément, ce qui

permet d'éviter d'éventuels dommages au treuil et au véhicule.

Remarque : si on n'utilise pas la trousse Ramsey, on doit se servir

d'une autre de conception équivalente.

Pour fixer les treuils REP, on peut également se procurer une goulotte

courte (251126, 60,02 cm, noire), moyenne (251127, 76,20 cm,

noire) ou longue (251128, 91,44 cm, noire). On recommande d’utiliser

une goulotte Ramsey pour toutes les installations utilisant des disposi-

tifs autres que ceux de cette société.

Remarque: se reporter aux sections suivantes relatives à chaque mod-

èle (REP 8000, REP 9000 de 12 V et REP 9000 de 24 V) pour savoir

comment raccorder les fils au moteur et au solénoïde. Les directives se

rapportant à tous les modèles se poursuivent à la page suivante.

REP 8000/9000 12V

Au moment de l'installation du treuil, raccorder les fils étiquetés

sortant du solénoïde aux bornes de moteur correspondantes, tel

qu’illustré à la FIGURE 3. SERRER FERMEMENT LES ÉCROUS

SUR LES BORNES (FIGURE 2). Relier le fil de terre du solénoïde

au boulon de mise à la masse au-dessous du moteur (le fil de

terre de l’accumulateur y est déjà raccordé).

Se servir de la pince pour fixer le solénoïde au moteur du treuil

(FIGURE 1). En installations « combinées », placer le solénoïde à

un angle d’environ 45° pour dégager le tube du protège-treuil

inférieur de la trousse d'installation. S’assurer que la pince soit

également dégagée des bornes inférieures du moteur. SERRER

FERMEMENT LA PINCE.

REP 9000 24V

Au moment de l'installation du treuil, raccorder les fils étiquetés

sortant du solénoïde aux bornes de moteur correspondantes, tel

qu’illustré à la FIGURE 4. SERRER FERMEMENT LES ÉCROUS

SUR LES BORNES. Relier le fil de terre du solénoïde à la vis n° 10

située sur la surface verticale du palier de l'extrémité moteur (FIG-

URE 4). Se servir de la pince pour fixer le solénoïde au moteur du

treuil (FIGURE 1). En installations « combinées », placer le

solénoïde à un angle d’environ 45° pour dégager le tube du pro-

tège-treuil inférieur de la trousse d'installation. S’assurer que la

pince soit également dégagée des bornes inférieures du moteur.

SERRER FERMEMENT LA PINCE.

FIGURE 1

FIGURE 2

REP 8000

REP 9000 12V

Vue A-A

FIGURE 3

Trou pour le boulon du fil

de terre du solénoïde

Vue A-A

REP 9000 24V

FIGURE 4

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Ramsey Winch REP 8000 Le manuel du propriétaire

Marque: Ramsey Winch

Modèle: REP 8000

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Ramsey Winch REP 8000 Le manuel du propriétaire

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