Ramsey Winch Company OWNER`S MANUAL Front Mount Electric
Contents
1. Congratulations You have purchased the finest winch available in its service Contents class The REP 6000 REP 8000 and REP 9000 feature a Safety Precautions highly efficient 3 stage planetary gear set The REP 6000 Tips for Safe Operation transmits torque from a permanent magnet D C motor while Techniques of Operation the REP 8000 and REP 9000 utilize a series wound D C Installation motor A safe positive clutch allows free spooling for quick Electrical Connections amp Operations cable deployment An automatic load holding brake is Maintenance designed to hold the full rated capacity of the winch Operating Instructions This winch was designed and manufactured to provide you Trouble Shooting Guide with the utmost in utility As with any device that combines Winch Parts List power and movement in its use there are dangers if improp Warranty erly used At the same time there are easier and faster wayYS Please Note Ramsey REP6000 REP8000 and REP9000 Series for getting the job done if certain precautions are taken first winches are designed for front mount vehicle use The winch Please read this manual carefully It contains useful ideas in es are not designed for and should not be used in industrial obtaining the most efficient operation from your Ramsey applications car haulers carriers wreckers hoisting etc Winch and safety procedures you need to know before begin and Ramsey does not warrant them to be suitable for such ning2. Note If recom mended mounting is not used a kit of equal design must be used Also available for mounting the REP winches are winch mounting channels short length 23 63 408052 black medium length 30 00 408120 black and long length 36 00 408101 black It is recommend ed 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 6000 and REP 8000 and REP 9000 12V and 24V models The combined installation instructions resume on the follow ing page REP 6000 When mounting winch attach solenoid wires to motor terminals at end of motor TIGHTEN NUTS ON MOTOR TERMINALS SECURELY Use solenoid clamp to attach solenoid assembly to winch motor see FIGURE 1 Position solenoid at about a 45 angle for clearance of lower winch guard tube of kit TIGHTEN CLAMP SECURELY SOLENOID ASSEMBLY SOLENOID CLAMP FIGURE 1 REP 8000 12V amp 24V 9000 12V When mounting winch connect labeled motor leads coming from solenoid assembly to appropriately marked motor terminals TIGHTEN NUTS ON MOTOR TERMI NALS SECURELY see FIGURE 3 Attach solenoid ground wire to grounding bolt located at bottom of motor See FIGURE 2 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 mou
3. Ramsey Winch Company RAMSEY OWNER S MANUAL WINCH Pie Front Mount Electric Winches REP 6000 REP 8000 REP 9000 REP 6000 REP 8000 REP 9000 Layer of Cable female Layer of Gable Rated Line Pull Per Ibs 6 000 5 000 4 400 3 800 Layer kg 2 720 2 260 1 990 1 720 Cumulative Cable Cap ft 20 50 80 100 Per Layer 1 4 6mm dia Cable m 6 15 24 30 Rated Line Pull Per Ibs 8 000 6 500 5 500 4 800 Layer kg 3 620 2 940 2 490 2 170 Cumulative Cable Cap Per ft 15 40 70 95 Rated Line Pull Per Ibs 6 200 5 400 4 Layer kg 4 070 3 300 2 800 2 440 2 Cumulative Cable Cap Per ft Layer 5 16 8mm dia Cable m Layer 5 16 8mm dia Cable m 4 12 21 28 Ibs NO 1 000 3 000 5 000 6 000 s Ibs NO 2 000 4 000 6 000 8 000 Line Pull First Layer kg LOAD 450 1 350 2 260 2 720 kg LOAD 900 1 810 2 720 3 620 FPM 25 21 16 10 8 FPM 12V MPM 7 6 6 4 4 8 3 24 Amp Draw 12V 70 155 240 370 440 Line Pull First Layer Line Pull First Layer Line Speed First Layer FPM 12V Line Speed First Layer ey 12V MPM 24V 12V 24V 24V 12V MPM 24V 12V 24V Line Speed First Layer Amp Draw Amp Draw Depends on cable being uniformly wound onto drum Ramsey performance data is compiled from actual winch testing
4. practical use a snatch block and double line arrange ment see illustration Neat tight spooling avoids cable binding which is caused when a load is applied and the cable is pinched between two others If this happens alternately power the winch in and out a few inches Do not attempt to work a bound cable under load free by hand Winches equipped with cable guide fairleads can pull from several directions Pull from an angle only to straighten up the vehicle oth erwise you can damage structural members or other parts of your vehicle and cause excess cable buildup on one end of the winch drum 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 recog nize 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 vehi Cle or a load while your vehicle is anchored in a station ary position The following sketches show you a few techniques When pulling a heavy load place a blanket jacket or tar paulin over the cable five or six feet from the hook It will slow the snap back in the event of a br
5. 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 1 2 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
6. or better and torque to 34 ft Ibs Place end of drum cable through fairlead and attach cable hook Use clevis pin and cotter pin see FIGURE 5 MOUNTING CHANNEL wa wenc X 1 44 LG eo HAWSE FAIRLEAD COTTER PIN WINCH MOUNTING BOLTS 3 8 I6NC X l i 4 LG CLEVIS PIN FIGURE 5 Hole for Solenoid Ground Wire Bolt A 1A A 1 2 View A A REP 9000 24v FIGURE 4 TO ENSURE PROPER ALIGNMENT P OF THE ROLLER FAIRLEAD TO THE DRUM POSITION SMALLER 7 16 SET j OF HOLES AT BOTTOM FOR MOUNTING N ROLLER FAIRLEAD DETAIL A beat eae REAR MOUNTING BOLT ATTACH BLACK GROUND CABLE TO NEGATIVE TERMINAL OF VEHICLE BA WINCH MOUNTED IN CHANNEL OR TO HORIZONTAL MOUNTING SURFACE Electrical Connections and Operations For normal self recovery work your existing electrical system is adequate Your battery must be kept in good condition A fully charged battery and proper connec tions are essential Run the vehicle engine during winch ing operations to keep battery charged The remote control switch is waterproof It has push but ton stations on either side It is designed this way to pre vent quick winch reversals which lead to solenoid fail ure 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 approp
7. supplied with the solenoid ANOaARWDNM 1 1 1 2 1 1 3 7 2 6 6 4 2 3 1 3 3 1 2 2 1 1 1 1 14 Solenoid Assembly Parts List REP 8000 9000 278158 REP 8000 9000 12V 278192 REP 8000 24V 278096 REP 9000 24V ete eile Ear Note All unidentified hardware comes e supplied with the solenoid no rega pareno __ Desevption 1 1 289015 Battery Cable 289091 Wire Assembly Black 16 Ga x 1 1 2 Lg 289092 Wire Assembly Black 6 Ga x 3 1 2 Lg 289171 Wire Assembly Motor Lead REP 8000 12V amp 24V REP 9000 12V 289115 Wire Assembly Motor Lead REP 9000 24V 289208 Wire Assembly Ground REP 8000 12V amp 24V REP 9000 12V 289209 Wire Assembly Ground REP 9000 24V 364002 Strap Copper 408102 Bracket 413024 Cover Solenoid 414053 Capscrew 1 4 20NCx1 1 4Lg Hx Hd Z P 416216 Screw 10 24NCX 1 2 Lg Rd Hd Z P 416227 Screw 10 24NCX 3 4 Lg Truss Hd Black 418004 Nut Hx Reg 10 24NC Z P 418014 Nut Hx Reg 1 4 20NC Z P 418140 Washer 10 SAE Flat Z P 418141 Lockwasher 10 Med Sect Z P 418149 Lockwasher 1 4 Med Sect Z P 418411 Nutsert 10 24NC 418514 Spacer 430013 Connector Female Molded 440071 Terminal Tab 440110 Solenoid REP 8000 9000 12V 440114 Solenoid REP 8000 9000 24V 440111 Strap Copper 482029 Cover Female Connector 1 1 3 3 1 1 2 1 1 3 7 2 6 6 3 2 3 3 3 1 2 2 2 1
8. tab is located on the gear housing end of the winch and operated as follows 1 To disengage the clutch move the clutch shifter lever to the OUT position Wire rope may now be free spooled off the drum 2 To engage the clutch move the clutch shifter lever to the IN position The winch is now ready for pulling Ramsey Electric Winches Troubleshooting Guide CONDITION POSSIBLE CAUSE CORRECTION MOTOR RUNS IN ONLY ONE 1 Defective solenoid or stuck solenoid 1 Jar solenoid to free contacts Check by applying 12 volts to DIRECTION coil terminal it should make an audible click when energized 2 Defective remote control switch 2 Disengage winch clutch remove remote control switch plug from the socket and jump pins at 8 and 4 o clock Motor should run Jump pins at 8 and 10 o clock Motor should run MOTOR RUNS EXTREMELY 1 Long period of operation 1 Cooling off periods are essential to prevent overheating HOT MOTOR RUNS BUT WITH 1 Insufficient battery 1 Check battery terminal voltage under load If 10 volts or INSUFFICIENT POWER OR WITH LOW LINE SPEED less replace or parallel another battery to it 2 Bad connection 2 Check battery cables for corrosion clean and grease 3 Insufficient charging system 3 Replace with larger capacity charging system MOTOR RUNS BUT DRUM 1 Clutch not engaged 1 If clutch engaged but symptom still exists it will be neces DOES NOT TURN sary to disassemble winch to deter
9. to the touch stop and let it cool for a few minutes Do not pull more than one minute at or near rated load Do not maintain power to the winch if the motor stalls Electric winches are for intermittent usage and should not used in constant duty applications Disconnect the remote control switch from the winch when not in use A Ramsey Part No 282053 safety on off switch in your vehicle is recommended Note Do not use winch in hoisting applications due to required hoist safety factors and features 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 O Ww m OQ m C A m 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 CAUTION CABLE INJURES AN KEEP CLEAR Tips for Safe Operation Don t underestimate the potential danger in winching ope
10. use When you follow our guidelines for operation your use Ramsey makes a separate complete line of winches for Ramsey Winch will give you many years of satisfying service industrial commercial use Please contact the factory for fur Thank you for choosing Ramsey You will be glad you have ther information one working for you AN CAUTION Read and understand this manual before installation and operation of winch See Safety Precautions CAUTION DO NOT USE WINCH IN LIFTING OR MOVING OF PERSONS Safety Precautions To Guard Against Possible Injury A minimum of five wraps of cable around the drum bar rel 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 Don t step over a cable or near a cable under load 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 Use a heavy rag or gloves to protect hands from burrs when handling winch cable Apply blocks to wheels when vehicle is on an incline 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 Keep the duration of your pulls as short as possible If the motor becomes uncomfortably hot
11. 1 15 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 Limited Lifetime Warranty Ramsey Winch offers a limited lifetime warranty for each new Ramsey winch against manufacturing defects in workmanship and materials on all manufac tured 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 purchas er 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 un
12. arranties 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 authori zation 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 RAMSEY WINCH RAMSEY WINCH COMPANY PO BOX 581510 TULSA OKLAHOMA 74158 1510 USA PHONE 918 438 2760 FAX 918 438 6888 e http www ramsey com inted in U S A Printed in U OM 914098 0107 P
13. 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 fas ten using 4 screws Tighten securely FIGURE 11 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 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 perform ance or may cause a Short Clean all connections espe cially 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
14. c NYLOK 414861 Capscrew 1 4 20NCx3 4 Lg Flat Hd Soc NYLOK 418018 Nut 1 4 20NC Hx Elastic Stop 418035 Nut 3 8 16NC Hx Reg Z P Thrust Disc Cable Assembly Cable Ground Gasket Capscrew 3 8 24NF x 1 2 HX HD ZP GR5 Screw 10 24NC x 3 8 Lg Hx Soc Hd ZP Shifter Lever Benn nnn OOan Asa sesan apse e 2 nwo HK ARADO AKRHR AD 13 Solenoid Assembly Parts List REP 6000 278154 REP 6000 ELLOW END TO MOTOR 20 HEAT SHRINK to roga parne ___ deserpton 2 289168 Wire Assembly Black 4 Ga x 6 Lg 289090 Wire Assembly Black 10 Ga x 3 Lg 289091 Wire Assembly Black 16 Ga x 1 1 2 Lg 289169 Wire Assembly Black 4 Ga x 3 1 2 Lg 364002 Strap Copper 408102 Bracket 413024 Cover Solenoid 414053 Capscrew 1 4 20NCx1 1 4Lg Hx Hd Z P 416216 Screw 10 24NCX 1 2 Lg Rd Hd Z P 416227 Screw 10 24NCX 3 4 Lg Truss Hd Black 418004 Nut Hx Reg 10 24NC Z P 418014 Nut Hx Reg 1 4 20NC Z P 418140 Washer 10 SAE Flat Z P 418141 Lockwasher 10 Med Sect Z P 418149 Lockwasher 1 4 Med Sect Z P 418165 Washer 5 16 Shakeproof External Teeth 418411 Nutsert 10 24NC 418514 Spacer 430013 Connector Female Molded 440071 Terminal Tab 440110 Solenoid 440111 Strap Copper 289015 Wire Assembly Battery Red 72 289141 Wire Assembly Battery Red 72 482029 Cover Female Connector Note All unidentified hardware comes
15. der 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 Important notice To the fullest extent permitted by applicable law the following are hereby excluded and disclaimed 1 All warranties of fit ness for a particular purpose 2 All warranties of merchantability 3 All claims for consequential or incidental damages There are no war ranties 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 w
16. en wrench slightly loosen all the capscrews and then snugly re tighten them in cross cross pattern but do not over tighten The ring gear must rotate by hand Re assemble the winch REP 6000 Oh Replacement Kit 251152 Included with REP 6000 H Replacement Kit 251183 Included with REP 6000 R REP 6000 PARTS LIST OE ee 247009 Gear Carrier Ass y Input Screw 6 32NCx3 8 Lg Fil Hd 247007 Gear Carrier Ass y Intermediate pies Nut 1 4 20NC Hx Reg Elastic Stop 247008 Gear Carrier Ass y Output 251110 Switch Ass y 251228 Cable Assembly 100 1 4 6MM Dia 278154 Solenoid Ass y 296181 Brake Shaft Ass y 332128 Drum Cable 334143 Gear Ring 334147 Gear Intermediate Sun 334154 Gear Input Sun 338249 End Bearing 412056 Bushing Drum 412061 Bushing Shaft 413018 Cover Gear Housing 414316 Capscrew 3 8 16NCx1 1 4Lg Hx Hd Gr 5 Z P 414829 Capscrew 1 4 20NCx1 Lg Soc Button Hd 414830 Capscrew 1 4 20NCx3 8 Lg Soc Button Hd 414861 Capscrew 1 4 20NCx3 4 Lg Flat Hd Soc NYLOK 418035 Nut 3 B 16NC Hx Reg Z P 418177 Lockwasher 3 8 ID Med Sect Plated 418181 Washer Flat 3 8 ID S A E Plated 424023 442207 444048 Gear Output Sun 448071 Cable Anchor 448049 Tie Bar 458109 Motor End Bearing Ass y 470053 Roll Pin 1 8 Dia x 3 8 477002 Locking Ring 477013 Cam Ring 477004 Ring Half 479007 Retainer Ring Gear 494077 S
17. fter knob needs to be positioned Place cam ring STOP POST ON over locking ring in proper position and RING TEAREEE confirm that shifter knob will move from lt engaged to disengaged position without interference Mark position of stop post on end bearing 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 Reassemble Gear Housing as shown in Figure 8 Make sure locking ring is positioned with stop post at marked location The capscrews item 38 for the retainer should be tightened to 40 45 in lbs Do not over tighten 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 FIGURE 10 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 confirm ing that the slot in the bushing is aligned with the key in the end
18. loosen the screws at the motor end without removing them Pull the Gear Housing assembly from the drum and shaft and set it down on the work bench with the Gear Housing Cover up Remove the drum bushing from the Gear Housing assembly or the end of the drum Set aside 2 Remove 6 capscrews from the Gear Housing Cover Holding the Gear Housing Cover over the Gear Housing assembly flip it over and set it on the workbench FIGURE 7 3 Gently lift the Gear Housing assembly working the gears bushings etc that are inside the Gear Housing out so that they are left stacked on the workbench See Figure 8 4 Turn the Gear Housing assembly over and as set on workbench Remove the Retainer 4 item 37 by removing six capscrews item 21 from Gear End Bearing item yy 13 Once the retainer is removed the Ring daa eee Gear item 10 Cam Ring item 36 7 CH SA and Locking Ring item 34 can be lifted off the end bearing Remove the six springs item 38 from the end bearing 12 FIGURE 9 17 Determine position shifter knob needs to RANGE OF POSITION be for your application Note Shifter FOR SHIFTER KNOB knob cannot be positioned too low or it will interfere with the feet on the Gear End cam ping Bearing See Range of Position in Figure SHIFTER END BEARING KNOB N A Wa To position the shifter knob place locking ring in end bearing with stop post approx imately 180 from where shi
19. mine cause and repair MOTOR WILL NOT OPERATE 1 Defective solenoid or stuck solenoid 1 Jar solenoid to free contacts Check solenoid by applying 12 volts to coil terminal it should make an audible click when energized 2 Defective remote control switch 2 Disengage winch clutch remove remote control switch plug from the socket and jump pins at 8 and 4 o clock Motor should run Jump pins at 8 and 10 o clock Motor should run 3 Defective motor 3 If solenoids operate check for voltage at armature post replace motor 4 Loose connections 4 Tighten connections on bottom side of hood and on motor MOTOR WATER DAMAGED 1 Submerged in water or water from 1 Allow to drain and dry thoroughly then run motor without high pressure car wash load in short bursts to dry windings CABLE DRUM WILL NOT 1 Clutch not disengaged 1 Check clutch operation according to nameplate Make sure FREESPOOL OR IS DIFFICULT clutch shifter knob is fully at OUT position TO FREESPOOL 2 Winch not mounted squarely causing 2 Check mounting to see that installation instructions on page end bearing to bind drum 4 have been followed 3 Some or all of the 6 414861 flat 3 Remove the gear housing cover 413018 and all gears head capscrews attaching the 479007 ring from inside the gear housing Disengage the clutch and check gear retainer are too tight to see that the ring gear will rotate by hand If it will not using a hex all
20. nting 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 TIGHTEN CLAMP SECURELY SOLENOID ASSEMBLY BATTERY CABLE BATTERY GROUND Pia WIRE GROUND WIRE FIGURE 2 A A A ty A g 7 1 F1 2 F2 N gt gt View A A View A A REP 8000 24v REP 9000 12v REP 8000 12v FIGURE 3 REP 9000 24V When mounting winch connect labeled motor leads com ing 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 bear ing 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 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 mount ing 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
21. oken cable Also open the vehicle hood for additional protection When anchoring to a tree always use a tree trunk pro tector i a 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 Ibs hitch truck to a tree or solid anchor and take out of gear To double the pull use 2 part line with snatch block and tie off to chassis Take out of gear Use the vehicle wheel power to help the winch but don t overtake the winch line Plan your pull You can t always hook up and pull out in one step Examine all the areas for anchoring possibilities as well as leverage situations direction and goal 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
22. pring 518020 Thrust Washer 518027 Thrust Disc 452005 Shifter Lever OMNDOAARWND Or mrA A f SS So SS Oo oo om or E EA o AE E A EE O E E E A E E an AAA A 11 REP 8000 pr lt OO RAPS SPE ERE OPE E OPE E SE E E E S gee 247005 247008 247024 251110 251118 278158 278192 296553 332128 334143 334145 338332 412056 412061 413018 414316 414370 414823 414830 414861 416273 ONTA Replacement Kit 251152 Included with REP 8000 H 1 Gear Carrier Ass y lntermediate Gear Carrier Ass y Output Gear Carrier Ass y Input Switch Ass y Cable Assembly 95 5 16 8MM Dia Solenoid Ass y 12v Solenoid Ass y 24v Brake Shaft Ass y Drum Cable Gear Ring Gear Intermediate Sun End Bearing Bushing Drum Bushing Shaft Cover Gear Housing Capscrew 3 8 16NCx1 1 4Lg Hx Hd Gr 5 Z P Capscrew 3 8 24NCx1 2 Hx Hd Z P GR5 Capscrew 1 4 20NCx3 4 Lg Soc Button Hd Capscrew 1 4 20NCx3 8 Lg Soc Button Hd Capscrew 1 4 20NCx3 4 Lg Flat Hd Soc NYLOK Screw 6 32NCx3 8 Lg Fil Hd 12 22 23 4 5 4 1 1 1 1 1 2 1 1 1 1 1 2 1 6 3 1 2 1 Pars no 418035 418177 418181 424023 442207 444048 444097 448046 448049 296589 296591 470053 477002 477013 477004 479007 494077 518020 518027 518019 452005 Included with REP 8000 R Description Nut 3 8 16NC Hx Reg Z P Lockwasher 3 8 ID Med Sect Pla
23. rations 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 inner most 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
24. ri ate 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 3 8 16NC TTACH BLACK GROUND CABLE 70 SE igh BL MINAL WINCH MOUNTED TO BUMPER OR TO VERTICAL MOUNTING SURFACE FIGURE 6 REP 6000 REP 8000 12V amp 24V REP 9000 12V Electrical Connections Route red and black battery cables up to battery CAU TION BE SURE BATTERY CABLES ARE NOT DRAWN TAUT ACROSS ANY SURFACES WHICH COULD POSSI BLY DAMAGE THEM Connect red cable to positive battery terminal and black cable to negative terminal REP 9000 24V Electrical Connections Route red and black battery cables up to battery CAU TION BE SURE BATTERY CABLES ARE NOT DRAWN TAUT ACROSS ANY SURFACES WHICH COULD POSSI BLY DAMAGE THEM Connect red cable to positive battery terminal Connect black ground cable to negative terminal of battery and to winch mounting bolt on motor end of winch see 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 Position winch as shown in Figure 6 Remove screws from tiebars You may be able to
25. ted Washer Flat 3 8 ID S A E Plated Clamp Gasket Gear Output Sun Gear Input Sun Cable Anchor Tie Bar Motor 12v Motor 24v Roll Pin 1 8 Dia x 3 8 Locking Ring Cam Ring Ring Half Retainer Ring Gear Spring Thrust Washer Thrust Disc Thrust Washer Shifter Lever REP 9000 a oo om oo os Oo os os os os os os os AN 247009 247022 247023 278158 278096 251110 296181 296385 328138 332193 334154 334147 334197 334171 338337 338282 412056 412061 Gear Carrier Ass y Input Gear Carrier Ass y Intermediate Gear Carrier Ass y Output Solenoid Ass y 12V Solenoid Ass y 24V Switch Ass y Brake Shaft Ass y 12V Brake Shaft Ass y 24V Cover Gear Housing Drum Cable Gear Input Sun Gear Intermediate Sun Gear Output Sun Gear Ring Output End Bearing End Bearing Motor 24V Bushing Drum Bushing Shaft Nut 3 8B 24NC Hx Reg Z P Lockwasher 3 8 Med Sect Z P 12V Lockwasher 3 8 Med Sect Z P 24V Washer Flat 3 8 ID S A E Z P Clamp Gasket Cover Gear Ring Input Cable Anchor Motor Electric 12V Motor Electric 24V Roll Pin 1 8 Dia x 3 8 Lg Locking Ring Cam Ring Ring Half Retainer Ring Gear Spring Thrust Washer 414316 Capscrew 3 8 16NCx1 1 4Lg Hx Hd Gr 5 Z P 414823 Capscrew 1 4 20NCx3 4 Lg Soc Button Hd 414830 Capscrew 1 4 20NCx3 8 Lg Soc Button Hd 414868 Capscrew 1 4 20NCx2 1 2 Lg Flat Hd So
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