Ramsey Electronics WILDCAT 80,000 LB Series Installation and user guide

OPERATING, SERVICE AND
MAINTENANCE MANUAL
WILDCAT SERIES 80,000 LB
INDUSTRIALWINCH
CAUTION:READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF
WINCH. SEE WARNINGS!

TABLE OF CONTENTS
WARRANTY INFORMATION...............................................................................................................1
SPECIFICATIONS................................................................................................................................1
WARNINGS ..........................................................................................................................................1
HYDRAULIC SYSTEM REQUIREMENTS ...........................................................................................2
CABLE INSTALLATION ......................................................................................................................3
CLUTCH OPERATION.........................................................................................................................4
WINCH OPERATION ...........................................................................................................................4
MAINTENANCE ...................................................................................................................................4
LUBRICATION TABLE ........................................................................................................................5
TROUBLE SHOOTING GUIDE ............................................................................................................5
INSTRUCTIONS FOR DISASSEMBLY................................................................................................6
DISASSEMBLY OF CARRIER ASSEMBLY ......................................................................................14
ASSEMBLY OF CARRIER ASSEMBLY............................................................................................15
CARRIER ASSEMBLIES ...................................................................................................................16
HOSE HOOKUP .................................................................................................................................17
PARTS DRAWING .............................................................................................................................18
PARTS LIST .......................................................................................................................................19
AIR CYLINDER ..................................................................................................................................20
DIMENSIONAL DRAWING ................................................................................................................21
LIMITED WARRANTY........................................................................................................................22

1 OM-914207-0211-D
RAMSEY HYDRAULIC PLANETARY WINCH MODEL WILDCAT 80K
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 "WARNINGS" 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 your winch, please follow instructions for prompt service on all warranty claims. Refer to back page for limited
warranty.
SPECIFICATIONS*
APPROXIMATE WEIGHT: 1700 LBS
WORKING PRESSURE: 2500 PSI
CABLE DIAMETER: 1 INCH
MAX FLOW: 60 GPM
LAYER
OF
CABLE
CABLE
CAPACITY
LOW SPEED HIGH SPEED
LINE PULL LINE SPEED LINE PULL LINE SPEED
Ft m Lb Kg fpm mpm Lb Kg fpm mpm
1 50 20 80000 36280 30 9 30000 13630 60 18
2 115 45 66600 30200 36 11 25000 11350 72 22
3 185 73 57100 25900 42 13 21400 9730 84 26
4 270 106 50000 22670 48 15 18700 8520 96 29
5 365 144 44400 20130 54 16 16600 7560 108 33
* These specifications are based on recommended wire rope of 1” Extra Improved Plow Steel Cable and a 9.0
cu. in. / Rev. motor.
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 WINCHING OPERATION.
DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
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 PEOPLE.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.
CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD.
BAND BRAKE IS NOT TO BE USED TO HOLD LOAD

HYDRAULIC SYSTEM REQUIREMENTS
Refer to the performance charts, below, to properly match your hydraulic system to winch performance.
The charts consist of:
(1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) line speed, first layer (FPM) vs. gallons per
minute (GPM). Performance based on a motor displacement of 9.0 cubic inches/rev with 60 GPM
maximum flow rate. Motor has (2) 1”-12 SAE straight thread o-ring ports.
Note: A motor spool (open center) directional control valve is required for brake operation.
PORT#3
COUNTER BALANCE/SPEED SELECTOR BLOCK
BRAKE
DIRECT LINE TO TANK
PAYOUT
COUNTER BALANCE
VALVE
RELIEF
4 WAY VALVE
3 POSITION
SYSTEM
PUMP
CUSTOMER
SUPPLIED
MOTOR CASE DRAIN
SAE -16
PORT #1
PORT #5
PAYIN
MOTOR 2 SPEED
1" TUBING SIZE
1" TUBING SIZE
SAE -16
LOW PRESSURE LINE
HIGH PRESSURE LINE
12 VDC
SHIFT SOLENOID
CLUTCH BAND BRAKE
80K AIR CONNECTIONS
PERFORMANCE CHARTS
BASED ON 9.0 CU IN/REV MOTOR
2 OM-914207-0211-D

CABLE INSTALLATION
1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of wire
rope, opposite hook, with plastic or similar tape to prevent fraying.
2. Place taped end of cable into slot on drum flange and bend into track on drum flange. Secure
using supplied u-bolt #62 and (2) nuts.
3. Carefully run the 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.
4. After installing cable, band brake is used to prevent bird nesting while pulling out cable, when
clutch is disengaged.
62
62
INSERT END OF CABLE
INTO SLOT AS SHOWN
BEND INTO TRACK
AS SHOWN
3 OM-914207-0211-D

4 OM-914207-0211-D
CLUTCH OPERATION
WARNING: CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.
To engage clutch:
1. Move clutch control to engage the clutch.
2. Run the motor in the cable out direction until the drum begins to turn.
WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD.
To disengage clutch:
1. Run the winch in the "cable out" direction until the load is off the cable.
2. Move the clutch control to disengage the clutch. The cable may now be spooled off.
WINCH OPERATION
The best way to get acquainted with how your winch operates is to make test runs before you use
it. Plan your test in advance. Remember, you hear your winch, as well as see it operate; learn to
recognize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or
shifting. Gain confidence in operating your winch and its use will become second nature with you.
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.
MAINTENANCE
Adhering to the following maintenance schedule will keep your winch in top condition and performing
as it should with a minimum of repair.
A. WEEKLY
1. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and
repair.
2. Check the pressure relief plug on the gear housing cover and the brake housing cover. Be sure they
are not plugged.
3. Lubricate cable with light oil.
4. Lubricate drum bushings with grease. It is necessary to remove cable to expose the grease zerks on
drum. Use high quality lithium grease for best results.
5. Apply a high quality lithium grease to clutch spline. Apply band brake to control drum. Declutch drum
and apply grease to spline between clutch and drum.
B. MONTHLY
1. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are
loose. Use grade 5 or better bolts.
2. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.
C. ANNUALLY
1. Drain the oil from the winch annually or more often if winch is used frequently.
2. Refill the winch to the oil level plug with all purpose GL-5 oil, (see page 5) for gear lube compatible with
your climate.
3. Inspect winch for damage and wear.

LUBRICATION TABLE
Min
Ambient&
Operating
Max
AmbientMaxOperating
80W140Synthetic ‐25(‐32) 125(52) 225(107)
75W90Synthetic ‐40(‐40) 115(46) 215(102)
80W90Conventional ‐20(‐29) 100(38) 180(82)
85W140Conventional 20(6) 120(50) 200(93)
TempRangeF(C)
*UseAPIGL‐5orEPlubricants.
LubricantDescription*
TROUBLE SHOOTING GUIDE
CONDITIONS POSSIBLE CAUSE CORRECTION
OIL LEAKS FROM WINCH 1. Seals damaged or worn.
2. Too much oil.
3. Damaged o-rings.
4. Case drain not connected.
1. Replace seal
2. Drain excess oil. Refer to page 6.
3. Replace o-rings.
4. Connect case drain.
WINCH RUNS TOO SLOW 1. Low flow rate.
2. Hydraulic motor worn out.
1. Check flow rate. Refer to HYDRAULIC
SYSTEMS performance chart on page 2.
2. Replace motor.
CABLE DRUM WILL NOT
FREESPOOL
1. Clutch not disengaged 1. Check operation. Refer to Clutch
Operation on page 4.
BRAKE WLL NOT HOLD 1. Incorrect directional control valve.
(cylinder spool, closed center).
2. Excessive hydraulic system back
pressure.
3. Sprag clutch worn out.
1. Use only a motor spool (open center)
directional control valve.
2. Reduce system back pressure to less
than 100 psi.
3. Replace sprag clutch mechanism.
BRAKE WILL NOT RELEASE 1. Brake line disconnected or blocked 1. Repair brake line.
WINCH WILL NOT
OPERATE AT HIGH SPEED
1. Shift solenoid not working. 1. Verify shift spool is energized.
WINCH OPERATES
ERRATICALLY ON INHAUL
1. Sprag hub is reversed. 1. Install sprag hub correctly.
5 OM-914207-0211-D

INSTRUCTIONS FOR DISASSEMBLY
1. Remove wire rope from drum.
2. Drain oil from winch by removing (2) plugs #54, removing the lower plug first.
3. When replacing lubricant, use 264 oz of applicable lube for your climate form table on page 5,
adding 4 oz at #44 and the remaining at # 55.
55
54
54
44
4. Remove (2) nuts #208b from air cylinder #208a. Air cylinder may now be removed. If needed,
mounting bracket #201 may be removed by removing pin #204 from pin #205 and then sliding
pin out of mounting bracket. Brake band #5 may be expanded over drum flange to barrel for
easiest removal.
NOTE:
BRAKE BAND FITS
OVER DRUM FLANGE
5
14
201
208b
208a
205
204
38
6 OM-914207-0211-D

5. Remove motor #45 from winch by first disconnecting hydraulic lines (see page 17), solenoid
wires, and then remove (4) bolts #73. O-ring #72 may now be removed.
6. Remove brake cover #42 by removing (4) bolts #66. The cover is spring loaded, use care
when removing. Remove o-ring #46 then springs #61 may be removed; residual oil may be
present in the brake housing.
7. Remove piston #11 including o-rings and backup rings #47, #48, #49, and #50 by using a
momentary puff of compressed air into the brake port located on top of the end bearing.
Capture the piston by placing a shop rag over the opening prior to using air.
8. Remove the sprag brake hub assembly #40, (7) stator plates #12, (6) disc brakes #13, and the
spacer #28. The sprag brake hub assembly #40 is not a serviceable part, if damaged a
replacement assembly should be ordered.
40
28
12
13
48
47
11
49
50
61
46
42
66
72
45
73
63
7 OM-914207-0211-D

9. Remove (8) cover bolts #36; cover #10, and o-ring #51.
10.Remove snap ring #58, and sun gear #17.
11.The planetary carrier assembly #4 may now be removed along with (2) spacers #24.
12.Remove second snap ring #58 and intermediate sun gear #16.
13.Planetary carrier assembly #3 may now be removed.
4
36
10
51
24
24
3
16
58
17
58
8 OM-914207-0211-D

14.Using a nylon strap, support ring gear #20 from a hoist or boom, this ring gear is heavy.
Remove (8) bolts #37 leaving the top most bolt for last. Remove the final bolt while supporting
ring gear. Set ring gear aside. Remove the o-ring #52.
15.Remove spacer #26 and the output sun gear #15.
16.Using a large pair of snap ring pliers remove the snap ring #60 from the shaft located inside
the planetary carrier assembly #2.
17.Using a nylon strap and hoist slide the output planetary carrier #2 from the ring gear housing.
The output planetary carrier is heavy.
18.Remove the spacer #27.
20
37
26
15
60
2
27
52
9 OM-914207-0211-D

19.Remove the clutch cylinder #1 by removing the (2) cotter keys #204 and (2) pins #206 from
either end of the air cylinder #207.
20.The clutch cylinder support angle #8 can be removed by removing the four bolts #66 and nuts
#65 attaching it to the mounting angles.
21.Remove the clutch yoke #29 by removing center pivot bolt #21 and nut #65.
8
29*
65
21
NOTE:
VIEW SHOWN LESS DRUM AND ANGLE CUT AWAY FOR CLARITY
65
29*
1
* CLUTCH YOKE #29 SHOWN REMOVED
AND PARTIALLY INSTALLED
FOR CLARITY
206
204
204
206
207
209
202
66
66
10 OM-914207-0211-D

22.By removing snap ring #58 and ball bearing #31, the input shaft #22 may be removed.
23.To remove the motor end bearing #18, support drum #14 with a nylon strap or chain and hoist.
Lift on the drum to tension the strap. Remove (6) bolts #67 and (6) nuts #68 attaching the end
bearing to the mounting angles #6 and #7. The motor end bearing #18 will be supported on the
output shaft end and may be slid off using a nylon strap and hoist to lift it.
67
68
18
22
31
58
7
14
67
6
11 OM-914207-0211-D

24.While continuing to support the drum #14, remove the clutch #9, snap ring #60 and spacer
#25.
25.The output shaft #23 may be slid from the drum assembly.
26.The drum #14 is now supported only by the nylon strap and maybe removed as needed.
27.The (2) bushings #34 may be pressed from the drum if replacement is necessary.
14
34
23
25
60
9
34
12 OM-914207-0211-D

28.To remove gear end bearing #18, from mounting angles #6 and #7, first remove (4) 7/8-9NC
bolts #67 and (4) nuts #68 from each angle. Shaft oil seal #56 and end bearing bushing # 33
can be removed and replaced at this time, if necessary.
67
18
67
68
68
33
56
7
6
13 OM-914207-0211-D

DISASSEMBLY OF CARRIER ASSEMBLY
Carrier assemblies may be purchased as a complete assembly (see pg. 19) or parts may be
purchased individually (see pg 16). If purchasing individual parts, it will be necessary to
disassemble the gear carrier as outlined below. Disassembly/ assembly of carriers utilizes the
same process for input carrier assembly #4, intermediate carrier assembly #3, and output
carrier assembly #2. Detail shown below is for intermediate carrier assembly#3. Please see
page 16 for detailed parts list and drawings of individual carriers.
1. Carefully drive roll pin #112 into carrier pin #111 so that it is captured within carrier pin #111
but not touching the opposite side of the intermediate carrier #102.
2. Tap carrier pin #111 to remove it from the intermediate carrier #102.
3. Place a plastic pail in a position to catch bearings #110, spacer #108 and washers #115, then
slide the gear #105 from the carrier assembly #102.
4. Remove the roll pin #112 from the carrier pin #111.
5. Repeat this process for the two remaining gears in the carrier.
INTERMEDIATE CARRIER
112
102
111
115
110
108
110
105
115
14 OM-914207-0211-D

15 OM-914207-0211-D
ASSEMBLY OF CARRIER ASSEMBLY
1. Place carrier #102 on flat clean surface.
2. A tool the width of the gear #105 and the diameter of the carrier pin #111 is helpful to install
needle bearings #110.
3. Place the gear #105 on a flat thin clean metal plate; metal plate should not be thicker than
thrust washer #115 and should be able to slide into gear pocket of carrier. Grease the inside of
gear and insert the greased tool described above into gear.
4. Place one row of needle bearings #110 into gear #102 carefully sliding them down the gap
between the tool and the gear so they stand vertically.
5. If more than one row of needle bearings is required, as shown in intermediate carrier, install
spacer #108, and the next row of needle bearings #110 as detailed in step 4 above until all
bearings are installed.
6. With tool remaining in place slide the gear #105 (resting on the thin plate) into position in the
carrier #102.
7. Place thrust washer #115 on top of gear #105. Insert planet pin #111 into carrier #105
8. Turn carrier #102 on its side so that the gear is on top. Remove the thin plate. Remove tool by
pushing planet pin #111 into carrier #102 until planet pin is at least half way past the last row of
bearings #110. The tool may now be removed completely.
9. Insert a thrust washer between gear #105 and carrier #102. Completely insert planet pin #111
into carrier #102 using care to align the roll pin hole in planet pin #111 with the roll pin hole in
the carrier #102.
10.Drive roll pin #112 into carrier #102 until roll pin #112 is flush with surface of the carrier #102.
11.Repeat this process to install the two remaining gears into the carrier.

CARRIER ASSEMBLIES
101
113
105
110
108
110
115
111
102
112
115
104
115
112
109
115
112
110
110
110
107
107
114
115
115
103
106
OUTPUT CARRIER*
Input Carrier*
INTERMEDIATE CARRIER*
* Input Gear Assembly may be purchased under part number 296672 * Intermediate Gear Assembly may be purchased under part number 296671
* Output Gear Assembly may be purchased under part number 296670
Item Qty Part No. Description
101 1 317018 Input Carrier
102 1 317019 Intermediate Carrier
103 1 317020 Output Carrier
104 3 334202 Output Planet Gear
105 3 334204 Intermediate Planet Gear
106 3 334206 Input Planet Gear
107 6 362306 Output Spacer
108 3 362307 Intermediate Spacer
109 102 402135 Input Needle Roller Bearing
110 204 402136 Intermediate Needle Roller Bearing
110 306 402136 Output Needle Roller Bearing
111 3 470113 Intermediate Carrier Pin
112 9 470036 Input, Inter. & Output Roll Pin
113 3 470111 Input Carrier Pin
114 3 470115 Output Carrier Pin
115 18 518067 Input, Inter. & Output Thrust Washer
16 OM-914207-0211-D

17 OM-914207-0211-D
HOSE HOOKUP
21
41
53
21
69
41
32
41
69
21
30
20
32
41

PARTS DRAWING
44
55
19
27
2
6015
2652
2037316
4581758
24
51
36 54 10
54 68
33 56 5
67
6
34 14 43 62
34 23
25 60 922
21
57 29
1
8
35
18
766
67
38
73
63
45
44
6111
474813
12
28
58
31
40
49
50
46
42
66
72
NOTES:
1. ITEM 1 - AIRCYLINDER KIT CONTAINS FASTENERS AND
CYLINDERS FOR CLUTCH AND BAND BRAKE.
2. ITEM 63 CONTAINS FASTENERS FOR BRAKE VALVE.
3. HOSE KIT CONTAINS FITTINGS AND HOSE.
68
65
1
24
74
65
62
18 OM-914207-0211-D