Ramsey Winch HD-P 4000 Operating instructions

Operating and Maintenance Manual
HD-P 4000
123966 PLANETARY WINCH
Mailing Address:
P.O. Box 58151
Tulsa, OK 74158
Phone: [phone]
Fax: [phone]
www.ramseyindustries.com
READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND
OPERATION OF WINCH. SEE WARNINGS.
CAUTION
OM 914307-0221-D

Congratulations!
You have purchased the finest winch available in its service class. It was designed and
manufactured to provide you with the utmost in utility. As with any device that combines
power and movement in its use, there are dangers if improperly used. Please read this
manual carefully. It contains useful ideas in obtaining the most efficient operation from
your Ramsey Winch and safety procedures you need to know before beginning use. When
you follow our guidelines for operation, your Ramsey Winch will give you many years of
satisfying service. Thank you for choosing Ramsey. You will be glad you have one working
for you.

Section Title Page
Introduction..........................................................................5
Winch Specifications ..............................................................7
Installation Details................................................................ 11
Winch Operation................................................................... 13
Maintenance ........................................................................15
Troubleshooting Guide............................................................17
Parts Identification ............................................................... 19
Limited Warranty..............................................................back cover
914307 3
Table of Contents

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Introduction
Introduction
Please read this manual carefully. This manual contains information to obtain the most efficient
operation from your Ramsey Winch and safety procedures you need to know before operating a
Ramsey Winch. Do not operate this winch until you have carefully read and understand the entire
manual. Ramsey Winches are designed and built to exacting specifications. Great care and skill
go into every winch we make. Refer to the last page for information on the Ramsey Winch
limited warranty. At the time of publishing, this manual is accurate to the best of our
knowledge. Ramsey Winch reserves the right to change any or all items, components and parts,
necessary for any reason. This right does not obligate Ramsey Winch to immediately update the
manual. If in doubt, please call Ramsey Winch for the most up-to-date information.
WARNING
Do not use the winch in hoisting applications due to required hoist safety factors
and features. Do not use the winch to lift, support or otherwise transportpeople
Do not allow personnel under or near the load.
Do not step over or near a cable under a load
Do not exceed the maximum line pull ratings shown in specifications.
Ensure that the clutch is fully engaged before starting the winching operation.
Do not exceed maximum line pull rating shown in tables. Shock loads must not
exceed these ratings.
Use proper personal protective equipment (PPE) including but not limited to
gloves and safety glasses when handling winch cable.
Do not disengage the clutch under load.
When pulling a heavy load, place a blanket, jacket, or tarpaulin over the cable five
or six feet from the hook.
Modification, alteration, or deviation to the winch should only be made by
Ramsey Winch Company.
Do not try to guide the cable during a loaded pull. Keep yourself and others a
safe distance to the side when pulling aload. Do not start the winch motor
before engaging the clutch.
When respooling cable, it is necessary to keep a slight load on the cable. While
wearing proper gloves, pull on the cable as the winch is wound in. Do not allow
the cable to slip through hands.
Do not approach the winch too closely.
Winch clutch should be disengaged when winch is not in use.
A motorspool (open center) directional control valve is required for brake
operation
A minimum of 5 wraps of steel cable around the drum barrel is necessary to hold
the load. Cable clamp setscrew is NOT designed to hold the load.
Do not maintain tension on winch cable during transport. Do not use winch as a
tie down.
CAUTION
Do not move the vehicle to pull load on the winch cable.
Avoid conditions where load shifts or jerks occur, as they may indicate a
dangerous situation
TIPS FOR SAFE OPERATION
Don’t underestimate the potential danger in winching operations.
Observe spooling of cable onto drum.Side pulls can cause cable to pile up at one
end of the drum.To correct uneven stacking, spool out the stacked section of
cable and move it to the other end of the drum and continue winching.Uneven
spooling of the winch cable can damage the winch.
Observe your winch while in use while maintaining asafe distance.
Do not attach tow hooks to winch mounting apparatus.During stationary, double
line pulls, then winch hook should be attached to the chassis of the vehicle.
Since the greatest pulling power is achieved on the innermost layer of the winch,
it is desirable to pull off as much line as possoble for heavy pulls.If necessary, use
asnatch block and double line arrangement.
Tight and neat spooling avoids cable binding.
DO NOT ATTEMPT TO WORK AROUND CABLE UNDER LOAD.
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Winch Specifications
Winch Specifications
Hydraulic System Requirements
•MOTOR SPOOL (OPEN CENTER) CONTROL VALVE REQUIRED
•2500 PSI RELIEF VALVE SETTING
•15 GPM FLOW RATE MAX -MOTOR AND WINCH MAY BE DAMAGED IF MAX FLOW RATE IS
EXCEEDED
•10 MICRON NOMINAL FILTRATION
Typical Layout shown below:
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for
wire rope ratings.
914307 7
15 GPM

Winch Specifications
Performance Charts
914307 8
11.75
9.25
90°
5.02 2.72
0.50
General Dimensions –Handle 276070
0
2000
4000
6000
0500 1000 1500 2000 2500 3000
Line Pull (Lbs.)
Pressure (PSI)
0
20
40
60
80
100
120
510 15
Line Speed (Ft/Min)
Flow (GPM)

Winch Specifications
General Dimensions –Winch 123966
914307 9
3.84
96,3
8.43
214,1
3.94
100,0
BAR R EL
0.50
12,7
C ABL E
ANCHOR
8.84
224,5
8.27
210,1
FL AN GE
7.49
164,8
1.25
31,7
8.38
213,1
4.25
107,9
2.21 56,1
2.21 56,1
4.19
106,4
8.38
212,7
9.96
252,9
5.01
127,3
11.34
288,0
5.67
144,0
5.28
125,2
5.51
139,9
4.33
109,9
2.16
55,1
(TYP)
1.18
29,9
(TYP)
7.65
194,3
26.48
647,2
.88
22,4
1.75
44,5
℄DRUM
℄DRUM
7/8-14 SAE POR T
(2-PLAC ES)1/2-13UNC X.92" D EEP
STEEL IN SER TS
(TYP 8-PL AC ES)

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Installation Details
Winch Mounting
ESSENTIAL MOUNTING INSTRUCTIONS TO MAINTAIN ALIGNMENT OF PLANETARY WINCH
COMPONENTS:
It is most important that this winch be mounted securely so that the three major sections (the
motor end, the cable drum, and the gear housing end) are properly aligned. Excessive bushing
wear and difficulty in free-spooling are usually symptoms of misalignment.
If the winch is foot mounted, then at least one tie-plate must remain mounted at midpoint of
winch to maintain alignment. It is always preferred to use BOTH tie-plates in the final installed
configuration.
When mounting the winch with other than the recommended Ramsey Angle Kit, the mounting
hole patterns described in the Dimensional drawings of this manual should be used. The
mounting surface must be flat within .015 inch and sufficiently stiff to resist flexing. If a steel
plate is used for foot mounting, it should be .750 inch thick. For this mounting application eight
(8) 1/2-13NC x 1-1/2” long grade 5 cap screws with lock washers will be needed to mount winch.
Cap screws should be tightened to 55 ft-lb (75 Nm) torque.
NOTE: If angles or a steel plate are used in mounting winch, tie-plates provided with winch are
to be attached to the remaining mounting pads, whether they be side or foot.
* CAUTION: If longer bolts
(minimum grade 5) are
substituted to mount winch or to
mount a roller guide at the side
mount pads, bolt length must be
such as to allow a minimum of
.50 inch thread length
engagement in the tapped holes
in side of each end bearing. Use
of excessive length bolts will
damage the winch and prevent
free-spool of the drum. Torque
bolts to 55 ft-lbs. (75 Nm).
914307 11
GEA R HOUSING EN
DRUM
MOTOR END
FOOT MOUNT SHIPPING STRA P

Installation Details
Cable Installation
An “A” or “B” decal on the clutch end bearing indicates the spooling direction of the cable. Also, a
letter “A” or “B” is stamped in the end bearing on the clutch end indicating rotation direction. If the
decal is damaged or unreadable, contact Customer Service for additional instructions to determine
proper direction. To reverse the rotation direction, exchange positions of the cartridge and plug
shown below.
1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of cable,
opposite hook, with plastic or similar tape to prevent fraying.
2. Place taped end of cable into hole in cable drum as shown below. Use the 3/8-16NC x 1/2” long
hex socket drive setscrew to secure cable to drum.
3. Carefully run winch in the "reel-in" direction. Keeping tension on end of cable, spool all the cable
onto the cable drum, taking care to form neatly wrapped layers.
After installing cable, check free-spool operation. Disengage clutch and pull on cable at a walking
speed. If cable “bird nests”, loosen jam nut and turn nylon setscrew clockwise to increase drag on
drum. If cable pull is excessive, loosen nylon setscrew by turning counterclockwise. Tighten jam
nut when proper setting is obtained.
CAUTION: OVER-TIGHTENING OF JAM NUT MAY STRIP NYLON SETSCREW.
914307 12

Winch Operation
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. Get to
recognize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or
shifting. Avoid conditions where load shifts or jerks occur, as they may indicate a dangerous
situation.
The uneven spooling of cable, while pulling the load, is not a problem, unless there is a cable
pileup on one end of the drum. If this happens, reverse the winch to relieve the load, and move
your anchor point further to the center of the vehicle. After the job is done you can unspool and
rewind for a neat lay of the cable.
When pulling a heavy load, place a blanket, jacket, and tarpaulin over the cable about five or six
feet behind the hook. In the event of a broken cable, this will slow the snap back of the cable and
could prevent serious injury.
The winch clutch allows rapid unspooling of the cable, from the cable drum, for hooking onto the
load. The clutch is operated by the clutch shifter lever.
WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD!
TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until the load is off the
cable. Pull handle out and rotate 90°. With handle in the “DISENGAGED” position, cable may now
be free-spooled from the drum.
TO ENGAGE CLUTCH: Pull handle out, rotate 90°and release handle. Run the winch in reverse
until the clutch handle snaps fully into the “ENGAGED” position. DO NOT attempt to pull a load
unless the handle is fully at the “ENGAGED” position.
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Maintenance
1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with broken
strands, replace immediately. Cable must be maintained per the manufacturer's instructions
for maintenance. Ramsey Winch does not manufacture cable.
2. Check that the clutch is fully engaging. See OPERATION instructions, above, for the appropriate
clutch shifter. FOR MANUAL CLUTCH ONLY: Monthly, disengage clutch, put several drops of oil
on the clutch handle shaft and work clutch handle IN and OUT several times to lubricate inside
the shifter assembly.
3. Check to see that the drum cable does not overrun (“bird nest”) when free-spooling.
4. Replace drum bushings and seals if seals begin to seep grease. Contact Ramsey Winch for
further details.
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Trouble Shooting Guide
CONDITIONS POSSIBLE CAUSE CORRECTION/ACTION
DRUM WILL NOT
ROTATE AT NO
LOAD
Winch not mounted squarely,
causing end bearing to bind up
Check mounting. Refer to Winch
Mounting.
Gears damaged Inspect and replace damaged
gears
DRUM WILL NOT
ROTATE UNDER
LOAD
Winch not mounted squarely,
causing end bearing to bind up
Check mounting. Refer to Winch
Mounting.
Load greater than rated capacity of
winch
Refer to Specifications page for line
pull rating.
Low hydraulic system pressure Check pressure. Refer to
Hydraulic System and
performance charts.
WINCH RUNS TOO
SLOW
Low hydraulic system flow rate Check flow rate. Refer to Hydraulic
System and performance charts.
Motor worn out Replace motor
DRUM WILL
NOT
FREESPOOL
Clutch not disengaged. Check Operation
Winch not mounted squarely,
causing end bearing to bind up
Check mounting. Refer to Winch
Mounting.
Side mounted bolts too long, causing
binding of ring gear
Check bolt length. Bolt thread
MUST NOT engage threaded holes
in sides of end bearing more than
the .50 inch thread depth in the
end bearing.
BRAKE WILL NOT
HOLD
Incorrect directional control valve
(cylinder spool-closed center)
Use only amotor spool (open
center) control valve.
LOAD DRIFTS Excessive Backpressure (100 PSI
Max.)
Check for restrictions in hydraulic
system. Refer to Hydraulic
System and performance charts.
CABLE BIRDNESTS
WHEN CLUTCH IS
DISENGAGED
Drag screw improperly adjusted Adjust nylon drag screw. Refer to
Cable Installation.
EXCESSIVE NOISE
Hydraulic system flow too high Check flow rate. Refer to Hydraulic
System and performance charts.
Drum in bind, winch not mounted
squarely
Check mounting. Refer to Winch
Mounting.
DRUM CHATTERS IN
“REEL IN”
DIRECTION
Low hydraulic system flow rate Check flow rate. Refer to Hydraulic
System and performance charts.
Low hydraulic system relief pressure
setting
Check relief valve setting.
OIL LEAKS FROM
BREATHER VENT
UNDER MOTOR END
BEARING
Damaged brake o-rings
, backup rings,
or sealing surfaces
Disassemble brake and inspect.
Contact Ramsey Winch for details.
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Parts Identification
914307 19
Winch 123966
3
4
2
15
22
45
44
19
23
29
37
26
24 41
43
7
33
31
35
30
8
32
34
5
6
36
14
25
11
18
17
21 20
38 46
12
18
39
27
9
40
47
10
13
1
42
23
23
28
16

Parts Identification
914307 20
Winch 123966
Item No. Quantity Part No. Description Item No. Quantity Part No. Description
1 1 234286 ASSEMBLY-DRUM 25 1432018 FITTING 7/16-20 90 degree
2 1 276069 SHIFTER ASSEMBLY 26 1442223 GASKET-MOTOR FLANGE
3 1 297125 ASSEMBLY-END BEARING, MOTOR SIDE 27 1444140 GEAR-RING
4 1 297126 ASSEMBLY-END BEARING, GEAR SIDE 28 1456038 FITTING-VENT, BREATHER
5 6 330011 STATOR-BRAKE 29 1458227 MOTOR-HYD
6 5 330012 DISC-BRAKE 30 1462067 O-RING-2.225 ID X .210 THK, 2-331
7 1 330013 PISTON-BRAKE 31 1462068 O-RING-3.10 ID X .210 THK, 2-338
8 1 330014 PISTON-BACKUP BRAKE 32 1462069 O-RING-2.975 ID X .210 THK, 2-337
9 1 334174 GEAR-OUTPUT SUN 33 1462070 RING-BACKUP, 3.143 ID X .076 THK, 8-338
10 1357588 SHAFT-INPUT 34 1462071 RING-BACKUP, 3.018 ID X .076 THK, 8-337
11 1364178 STRAP-SHIPPING 35 1462072 RING-BACKUP, 2.268 ID X .076 THK, 8-331
12 1395521 TIE PLATE 36 1462073 O-RING-3.234 ID X .139 THK, 2-236
13 1412196 BUSHING-DRUM,GEAR END 37 1470033 SPIROL PIN-1/8 X 7/8
14 1412197 BUSHING-DRUM, MOTOR END 38 1472052 PLUG-SAE O-RING,.562-18NF
15 4414159 CS-5/16-18UNCX2.50, HXHD, GR5, ZP, N/P 39 1486080 SEAL-GEAR HOUSING
16 2414854 SCREW-1/4-20NCX1/2LG, RDHD, SLOT, Z/P 40 2490003 SNAP RING
17 1414926 SETSCREW-3/8-16NC X1, SOCKET, NYLON 41 1490049 RING-INTERNAL RETAINING
18 8414947 CAPSCREW-1/2-13NC X 1 LG,HEX SOC HD 42 1490066 RING-INTERNAL RETAINING
19 2414954 CAPSCREW 1/2-13NC X 1/3/4 LG. SOCHD Z/P 43 9494124 SPRING-BRAKE
20 1416016 SETSCREW1/4-20NCX1/4 HX SOCK HD CUP 44 1509132 TUBE-BRAKE RELEASE
21 1418036 NUT-3/8-16 NC, HEX JAM, Z/P 45 1516041 VALVE-MOTOR
22 4418163 LOCKWASHER-5/16 MED SECT, Z/P 46 1518037 THRUST WASHER
23 12 418218 LOCKWASHER-1/2 ID MED SECT,Z/P 47 1518047 WASHER-THRUST
24 1431019 COUPLING-MOTOR