Ramsey Winch HD-P8000 Installation and user guide

OPERATING, SERVICE AND
MAINTENANCE MANUAL
MODEL HD-P8000
PLANETARY WINCH
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE
INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!

TABLE OF CONTENTS
INTRODUCTIONS ...........................................................................................1
WARRANTY INFORMATION ...........................................................................1
SPECIFICATIONS ...........................................................................................1
WARNINGS.......................................................................................................1
CABLE INSTALLATION ...................................................................................2
HYDRAULIC SYSTEM REQUIREMENTS .......................................................3
TYPICAL LAYOUT ...........................................................................................3
PERFORMANCE CHARTS ..............................................................................3
OPERATION ....................................................................................................4
MAINTENANCE ...............................................................................................4
TROUBLE SHOOTING GUIDE ........................................................................5
OVERHAUL INSTRUCTIONS ..........................................................................6-11
DIMENSIONAL DRAWINGS ............................................................................12-13
PARTS LIST AND PARTS DRAWINGS ...........................................................14-17
LIMITED WARRANTY ...................................................................BACK COVER

1
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.
WARNINGS:
• A MOTOR SPOOL (OPEN CENTER) DIRECTIONAL CONTROL VALVE IS REQUIRED FOR BRAKE OPERATION.
• CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCH.
• DO NOT DISENGAGE CLUTCH UNDER LOAD.
• DO NOT LEAVE CLUTCH ENGAGED WHEN WINCH IS NOT IN USE.
• STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS.
• STAND CLEAR OF CABLE WHILE PULLING. DO NOT TRY TO GUIDE CABLE.
• DO NOT EXCEED MAXIMUM LINE PULL RATINGS SHOWN IN TABLE.
• DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PERSONNEL.
• A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD. CABLE CLAMP
(SETSCREW) IS NOT DESIGNED TO HOLD LOAD.
• IN CAR CARRIER APPLICATIONS, AFTER PULLING VEHICLE ON CARRIER, BE SURE TO SECURE VEHICLE TO CARRIER
BED. DO NOT MAINTAIN LOAD ON WINCH CABLE WHILE TRANSPORTING VEHICLE. DO NOT USE WINCH AS A TIEDOWN.
• WHEN PULLING A HEAVY LOAD PLACE A BLANKET, JACKET, OR TARPAULIN OVER THE CABLE FIVE OR SIX FEET FROM
THE HOOK.
• AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR, AS THEY MAY INDICATE A DANGEROUS SITUATION.
Rated Line Pull (lbs.) …………………………………………………
…
8,000
(Kg.) …………………………………………………
…
3,620
Gear Reduction 5.1:1
HD-P8000 STD. ……..…....………. 82 lbs. (37.2 Kg)
HD-P8000 "Y" ………….………….. 76 lbs. (34.5 Kg)
12345
lbs. 8,000 6,800 5,900 5,200 4,700
Kg. 3,620 3,080 2,670 2,350 2,120
ft. 25 55 90 130 170
m 7 16 27 39 51
ft.15356085115
m 4 10 18 25 34
FPM5058677684
MPM 15.2 17.6 20.3 23.1 25.5
…………………………………………………………
…
Weight (without cable)
LAYER OF CABLE
*Rated line pull
per layer
HD-P8000 (STD.
DRUM)
* Line Speed (at
15 GPM)
HD-P8000 ("Y"
DRUM)
* Cable Capacity per Layer
PLEASE READ THIS MANUAL CAREFULLY
This manual contains useful ideas for obtaining the most efficient operation from your Ramsey Winch, and safety pro-
cedures one needs to know before operating a Ramsey Winch. Do not operate this winch until you have carefully read
and understand the "WARNING" and "OPERATION" sections of this manual.
WARRANTY INFORMATION
Ramsey Winches are designed and built to exacting specifications. Great care and skill go into every winch we make.
If the need should arise, warranty procedure is outlined on the back of your self-addressed postage paid warranty
card. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company. If you have any
problems with your winch, please follow instructions for prompt service on all warranty claims. Refer to back page for
limited warranty.
SPECIFICATIONS*

2
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 direc-
tion, 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. Insert the end of the cable through roller fairlead.
3. Place taped end of cable under tensioner plate and into hole in cable drum. Use the 3/8-16NC x 1/2” long hex
socket drive setscrew (included with drum assembly) to secure cable to drum.
4. Carefully run winch in the "reel-in" direction. Wind about 5 wraps of cable onto the drum and stop. Using a ham-
mer tap these five wraps tightly over against the cable anchor flange of the drum. Spool all the cable onto the
cable drum, taking care to form neatly wrapped layers.
After installing cable, check freespool operation. Disengage clutch and pull on cable at a walking speed. If cable
“birdnests”, loosen jam nut (item #20) and turn nylon setscrew (item #17) 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.
(REEL IN) RAISE INLET
"A" ROTATION "B" ROTATION
CABLE DRUM
ROTATION DIRECTION CABLE DRUM ROTATION DIRECTION
CARTRIDGE
POSITION CARTRIDGE
POSITION
PLUG
POSITION
17
20
INSERT CABLE AS SHOWN FOR "A" ROTATION
OVERWOUND APPLICATION.
(UNDERWOUND APPLICATION REQUIRES CABLE TO
COME UNDER DRUM FROM OPPOSITE DIRECTION
AND INSERTED IN THIS SAME CABLE POCKET.)
INSERT CABLE AS SHOWN FOR "B" ROTATION
OVERWOUND APPLICATION.
(UNDERWOUND APPLICATION REQUIRES CABLE TO
COME UNDER DRUM FROM OPPOSITE DIRECTION
AND INSERTED IN THIS SAME CABLE POCKET.)
"B" ROTATION
DIRECTION
"A" ROTATION
DIRECTION
SETSCREW
NOTE: VIEW SHOWN WITHOUT
CABLE TENSIONER FOR CLARITY.
CABLE IN DIRECTION CABLE IN DIRECTION

3
HYDRAULIC SYSTEM REQUIREMENTS
Refer to the performance charts below to properly match your hydraulic system to the
winch performance. The charts consist of:
(1) Line Pull first layer (lb.) vs. Working Pressure (PSI)
(2) Line Speed, first layer (FPM) vs. flow (GPM)
SYSTEM REQUIREMENTS
MOTOR SPOOL (OPEN CENTER) CONTROL VALVE REQUIRED
2500 PSI RELIEF VALVE SETTING
15 GPM FLOW RATE
DO NOT EXCEED 20 GPM--MOTOR AND WINCH MAY BE DAMAGED
10 MICRON NOMINAL FILTRATION
PORT CONTROL
PUMP
(.75 I.D. MINIMUM)
LOW PRESSURE LINE
(.50 I.D. MINIMUM)
HIGH PRESSURE LINE
2500 PSI
15 GPM
RATED LOAD:
PRESSURE AT
MAX. FLOW &
(MOTOR SPOOL)
4 WAY VALVE
3 POSITION RELIEF
SYSTEM
A
PORT
BRAKE
MOTOR
WITH BRAKE RELEASE SHUTTLE TYPICAL LAYOUT
B
WORKING PRESSURE (PSI) AT 15 GPM
GALLONS PER MINUTE (GPM)
LINE PULL-FIRST LAYER (LB)
LINE SPEED-FIRST LAYER (FPM)
051015
10
20
30
40
0
0
1000
2000
3000
4000
5000
6000
7000
8000
1000 2000 2500
50
BASED ON 15.5 CU. IN. MOTOR
1500500
PERFORMANCE CHARTS

4
OPERATION
The best way to get acquainted with how your winch operates is to make test runs before you
actually use it. Plan your test in advance. Remember, you hear your winch as well as see it oper-
ate. 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 dan-
gerous 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 or air shifter.
WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD!
MANUAL CLUTCH SHIFTER (Refer to dimensional drawing page 12):
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 re-
lease 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.
AIR CYLINDER CLUTCH SHIFTER (Refer to the dimensional drawing page 13):
TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the
cable. Apply air pressure to the .125-27 NPT port: 80 PSI (min.)-150 PSI (max.). CAUTION:
PRESSURE MUST NOT EXCEED 150 PSI. TO ENGAGE CLUTCH: Remove air pressure from
the cylinder (a return spring engages the plunger). Run winch in reverse until the clutch engage-
ment indicator light (green light) is lit. To install light to the vehicle electrical system refer to the
Electrical Schematic on page 13.
MAINTENANCE
1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with bro-
ken strands, replace immediately. Cable and hook assembly (100’ long cable) P/N 524118
may be purchased from a Ramsey distributor.
2. Check that the clutch is fully engaging. See OPERATION instructions, above, for the appro-
priate 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 (“birdnest”) when freespooling. Refer to
page 2 if it does.
4. Replace drum bushings and seals if seals begin to seep grease. Refer to the Overhaul In-
structions, pages 6-11. Add additional lubricant, Mobilith SHC 007, to gears and drum bear-
ings if required.

5
TROUBLESHOOTING 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.
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.
Load greater than rated capacity of winch Refer to Specifications page 1 for line
pull rating.
Low hydraulic system pressure Check pressure. Refer to Hydraulic
Systems per-formance charts, page 3.
WINCH RUNS TOO SLOW Low hydraulic system flow rate Check flow rate. Refer to System
Requirements and Typical Layout,
page 3.
Motor worn out Replace motor
DRUM WILL NOT FREESPOOL Clutch not disengaged. Check Adjustment of Manual
Shifter, page 10. Check Operation, page 4.
Winch not mounted squarely, causing end bearing to bind
up Check mounting.
Side mounted bolts too long, causing binding of ring gear
(Item #32, page 14). 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 a motor spool (open center) control valve.
LOAD DRIFTS Excessive Backpressure (100 PSI Max.) Check for restrictions in hydraulic
system. Refer to System Requirements
and Typical Layout, page 3.
CABLE BIRDNESTS WHEN CLUTCH
IS DISENGAGED Drag screw improperly adjusted Adjust nylon drag screw. Refer to
Cable Installation, page 2.
EXCESSIVE NOISE Hydraulic system flow too high Check flow rate. Refer to Typical
Layout page 3.
Drum in bind, winch not mounted squarely Check mounting.
DRUM CHATTERS IN “REEL IN”
DIRECTION Low hydraulic system flow rate Check flow rate. Refer to Typical
Layout page 3.
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. See
Overhaul Instructions, pg. 7.

6
INSTRUCTIONS FOR OVERHAUL HD-P8000 SERIES WINCH
Take note of mounting configurations for proper mounting of parts during re-
assembly. Replace all gaskets, o-rings, and seals during re-assembly.
Disconnect tube (item #49) from elbow fittings (items #30) on bottom of end bearing
and counterbalance valve (item #50). Remove motor (item #34) from end bearing by
slowly unscrewing capscrews (items #22). CAUTION: MOTOR IS UNDER SPRING
PRESSURE.
Check breather vent (item #33). Make sure it is not clogged. If oil is leaking from vent,
check brake o-rings, backup rings, and sealing surfaces (see page 7).
Remove springs (items #48) from pockets and inspect for damage.
Replace gasket (item #31).
Remove coupling (item #29) from end bearing. Examine coupling for signs of wear, re-
place if necessary. If necessary, remove counterbalance valve from motor by removing
capscrews (items #16).
22
28
34
31
29
16
26
50
49
30 48

7
Remove retaining rings (items #46 and #47) with screwdriver.
Remove brake parts from end bearing. NOTE POSITION OF O-RINGS AND BACKUP
RINGS BEFORE REMOVAL. Examine brake discs (items #7) and stators (items #6) for
signs of wear, and replace if necessary.
Examine o-rings (items #35 and 36) and backup rings (items #38 and 40) in brake piston (item
#8), as well as o-ring (item #37) and backup ring (item #39) in backup brake piston (item #9)
for signs of wear. Remove o-rings and backup rings from grooves in brake piston or backup
brake piston and replace if necessary.
46
8
38 36
40
35
9
37 39
6
7
47

8
Remove nuts (item #66), washers (item #28), springs (item #60), and capscrews (item #55) from spring
tensioner. Spring tensioner may be left partially assembled when removing capscrews (item #65). Refer
to exploded views on pages 14 and 16 for all components. CAUTION: Both tensioner assembly and
mounting angle (item #3) will come off at the same time when mounting angle capscrews (item
#65) are removed. Slide motor end bearing (item #11) and drum (item #1) from gear housing end bear-
ing.
Remove input shaft (item #13) from end bearing. Inspect shaft and output sun gear (item #10) for dam-
age and replace if necessary. To remove the output sun gear, remove the snap rings (items #45) and
thrust washer (item #52) and pull off the end of the shaft.
Remove bushing (item #15) and o-ring (item #41) from motor end bearing. Place new, well-oiled o-ring
into groove inside of end bearing and press new bushing onto end bearing.
Remove seal (item #44) from gear housing end bearing
(item #12). Loosen nut (item #24) and remove nylon set-
screw (item #21). Remove ring gear from gear housing end
bearing, if necessary. Remove bushing (item #14) from end
bearing. Press new bushing into end bearing. Install ring
gear, then nylon setscrew and nut. Ring gear must be fully
seated in end bearing and slot in ring gear MUST NOT be
aligned with clutch shifter hole. Install new seal in end bear-
ing, with sharp edge of seal outward. 21 24
44
32
12
14
1
19
2
65
3
13
10 52
45
11
41
15
60
28
66
55