Ramsey Winch Sierra H8 Installation and user guide

Ramsey Winch Company
P
.O. Box 58151 - Tulsa, OK, 74158-1510 USA
Phone [phone] - Fax [phone]
http://www.ramsey.com
Operation, Service and Maintenance Manual
Sierra H8 Hydraulic Winch

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Table of Contents
Introduction 4
Pictogram Definitions 5
Sierra H8 Specifications 8
Winch Mounting 10
Cable Installation - Set Screw 11
Sierra Hydraulic Winch Operation 12
Sierra Troubleshooting Guide 13
Overhaul Section - Disassembly 14
Overhaul Section - Assembly 25
Assemblies and BOMs 36
Dimensional Drawing -Manual Shift 48
Dimensional Drawing - Air Shift 49
Limited Warranty 51
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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 your local Ramsey Winch distributor for the most up-to-date
information.
Warnings
Ensure the clutch is fully engaged before starting the winching operation.
Do not start the winch motor before engaging the clutch.
Do not disengage the clutch under load.
Do not allow personnel under or near the raised load.
Do not try to guide the cable during a pull. Stand clear of the cable.
Do not exceed the maximum line pull ratings shown in specifications.
Do not use the winch to lift, support, or otherwise transport people.
Always maintain a minimum of five wraps of cable around the drum. This is
necessary to hold the load. The cable anchor is not designed to hold the load.
In car carrier applications, after pulling the vehicle onto the carrier, secure the
vehicle to the carrier bed. Do not maintain load on winch cable while transporting
the vehicle. Do not use the winch as a tie down.
When pulling a heavy load, place a blanket, jacket, or tarpaulin over the cable five or
six feet from the hook.
Do not allow the load to shift or jerk.
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Pictogram Definitions
Read and understand this entire manual before using the winch.
Clutch must be fully engaged during winching operations.
Do not disengage clutch under load.
Keep all personnel out from under and away from raised loads.
Do not use the winch to lift, support, or otherwise transport people.
Do not exceed maximum line pull ratings shown in specifications. Shock loads must not exceed these ratings.
Keep yourself and others at a safe distance to the side of the cable when pulling under load. Do not step over a cable, or
near a cable under load.
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Do not use the winch in hoisting applications due to the required hoist safety factors and features.
Do not try to guide the rope during winching operations.
Always wear the appropriate personal protection equipment during winching operations.
Illustrates the engaged and disengaged positions for the clutch handle on winches with a manual clutch.
Illustrates the engaged and disengaged positions for the clutch handle on winches with a semi-automatic clutch.
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Illustrates the engaged and disengaged positions on winches with electric shift.
Illustrates the engaged and disengaged positions on winches with air shift.
The winch is intended to be used for vehicle recovery and pulling loads.
This image illustrates the minimum number of wraps of rope for the particular winch.
The blanks on these images will have printed data specific to the particular winch.
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Sierra H8 Specifications
Performance Table
SIERRAH8
RATEDLINEPULL lbs. 8000
kg. 3620
GEARREDUCTION 17
WEIGHT(WITHOUTCABLE) 90 lbs.
LAYEROFCABLE 1 2 3 4 5
*RATEDLINEPULL
PERLAYER
lbs. 8000 6700 5700 5000 4500
kg. 3620 3040 2585 2270 2040
CABLECAPACITY ft. 25 55 90 130 175
m 7.6 16.7 27.4 39.6 53
LINESPEED
(AT17 GPM)
fpm 48 56 64 73 81
mpm 14.5 17.0 19.4 22.1 24.6
*These specifications are based on recommended 3/8" EIPSwire rope and a 4.8 Cu. In./Rev motor.
Performance Charts
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Hydraulic System Layout
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Winch Mounting
It is important to mount the winch securely so the three major sections (the motor end, the cable drum, and the gear
housing end)are properly aligned. Excessive bushing wear and difficulty freespooling are usually symptoms of
misalignment.
If the winch is mid-mounted, attach at least one tie-plate to the mounting feet at the bottom of the winch to maintain
alignment. If the winch is foot mounted, attach at least one tie-plate at the midpoint to maintain alignment. It is always
preferred to use both tie-plates in the final installed configuration.
Contact your local RAMSEYWINCHdistributor or RAMSEYWINCHcustomer service for the recommended mounting
kit. The mounting kit will allow the winch to be mounted in upright or midmount applications and meets the criteria of
serving as a solid and true mounting surface.
If not using the RAMSEYWINCHmounting kit, or a RAMSEYWINCHmounting kit is not available, use the mounting
hole patterns described in the Dimensional drawings. The mounting surface must be flat within 0.015 in. and sufficiently
stiff to resist flexing.
If angles or a steel plate are used in mounting the winch, attach the provided tie-
plates to the remaining mounting pads to the either the side or foot.
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Cable Installation - Set Screw
An "A" or "B"decal on the motor end bearing indicates the spooling direction of the cable. If the decal is damaged or
unreadable, contact Customer Service for addition information.
1. Unwind the cable by rolling it out along the ground to prevent kinking. Securely wrap the end of the cable opposite
of the hook with plastic or similar tape to prevent fraying.
2. Place the taped end of the cable into the hole in cable drum. Use the 3/8-16NCx 1/2"long hex socket drive
setscrew to secure the cable to the drum. The setscrew is included with the drum assembly.
3. Carefully run the winch in the "reel-in" direction. Keeping tension on the end of the cable, spool all the cable onto
the cable drum, taking care to form neatly wrapped layers.
4. With the cable installed, check the freespool operation. Disengage the clutch and pull on the cable at a walking
speed. If the cable "birdnests," loosen the jam nut and turn the capscrew clockwise to increase drag on the drum.
If the cable pull is excessive, loosen the capscrew by turning counterclockwise. Tighten the jam nut when the
proper setting is obtained.
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Sierra Hydraulic Winch Operation
Familiarize yourself with winch by making test runs before the first pull. Plan your test in advance. You hear your winch
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 the drum.
If this happens, reverse the winch to relieve the load and move your anchor point closer to the center of the vehicle.
After the job is done you can unspool and rewind to neatly lay the cable.
Manual Clutch Operation
To disengage the clutch:
1. Run the winch in the "cable out"direction until the load is off the cable.
2. Pull the handle out and rotate 90°.
3. With the handle in the "DISENGAGED"position the cable can now be free-spooled from the drum.
To engage the clutch:
1. Pull the handle out and rotate 90° and release the handle.
2. Run the winch in reverse until the clutch handle snaps fully into the "ENGAGED" position.
3. Do not attempt to pull a load unless the handle is fully at the "ENGAGED" position.
4. Do not force the handle or hammer the handle to engage.
Air Clutch Operation
To disengage the clutch:
1. Run the winch in the reverse (reel out) direction until the load is off the cable.
2. Apply air pressure to the 0.125-27 NPTport. 80 PSI(min.) 150 PSI(max.). Pressure must not exceed 150 PSI.
To engage the clutch:
1. Remove air pressure from the cylinder (a return spring engages the plunger).
2. Run the winch in reverse until the clutch engages. Do not attempt to pull a load with the clutch not engaged.
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Sierra Troubleshooting Guide
CONDITIONS POSSIBLECAUSE CORRECTION
DRUMWILLNOTROTATEWITH
NOLOAD
1. Winch not mounted squarely causing
end bearings to bind the drum.
2. Brake damaged.
3. Gears damaged.
1. Check the mounting. Verify it's
square.
2. Inspect and replace brake.
3. Inspect and replace damaged
gears.
DRUMWILLNOTROTATE
UNDERLOAD
1. Load greater than rated capacity of the
winch.
2. Low hydraulic system pressure.
3. Winch not mounted squarely causing
end bearings to bind the drum.
1. Reduce load to less than the
rated capacity of the winch.
2. Check pressure.
3. Check the mounting. Verify it's
square.
WINCHRUNSTOOSLOW 1. Low flow rate.
2. Hydraulic motor worn out.
1. Check flow rate.
2. Replace motor.
DRUMWILLNOTFREESPOOL 1. Clutch not disengaged.
2. Winch not mounted squarely causing
end bearings to bind thedrum.
1. Disengage clutch.
2. Check the mounting. Verify it's
square.
BRAKEWILLNOTHOLD 1. Brake damaged. 1. Inspect and replace brake.
LOADDRIFTS 1. Worn brake. 1. Overhaul the brake assembly.
CABLEBIRDNESTSWHENTHE
CLUTCHISDISENGAGE
1. Drag screw improperly adjusted. 1. Adjust drag screw.
EXCESSIVENOISE 1. Hydraulic system flow too high.
2. Drum in bind, winch not mounted
squarely.
1. Check flow rate.
2. Check the mounting. Verify it's
square.
DRUMCHATTERSin "REELIN"
DIRECTION
1. Low hydraulic system flow.
2. Low hydraulic system relief pressure
setting.
1. Check flow rate.
2. Check relief valve setting.
CLUTCHDIFFICULTTO
ENGAGE
1. Detent screw damaged or improperly
adjusted.
1. Replace or readjust detent screw.
13 914281 - 1016 - A

Overhaul Section - Disassembly
Tie Bar Removal
1. Remove the capscrews (#9) to remove the tie plates (#7).
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Motor Assembly Removal
1. Carefully remove the spring retention plate (#8) by removing the capscrews (#11). Remove the washers (#12).
Remove the spacers (#6) from the spring tensionser assembly (#3) and remove the spring tensioner assembly.
Remove the motor assembly (#2) from the winch.
2. Remove the thrust disc (#19), spring (#18), and drag brake (#4) from the motor assembly. Remove the capscrew
(#20) and jam nut (#13) from the motor assembly.
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Drum Removal
1. Pull the input coupling (#14) out of the drum (#15). Drive the roll pin (#16) out of the coupling (#14).
2. Pull the shaft (#5) out of the drum. Remove the O-ring (#20)from the shaft (#5).
3. Lift the drum (#15) off of the gear housing assembly and remove the dowel pins (#17).
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Removing the Brake Cover
1. Set the gearbox assembly with the output side down.
2. Remove the brake housing (#103) by removing the capscrews (#111) and sealing washers (#119). The dowel
pins (#124) will be loose when the brake housing is removed.
3. Remove the brake cover (#102) by removing capscrews (#110). Remove the O-ring (#116) from the brake hous-
ing (#103).
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Removing the Brakes
1. Remove the wave washers (#121), stator plate (#104), the brake disc (#114), two separator plates (#105), the
brake disc, the stator plate, the brake disc, and the cam (#107).
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Removing the Brake Hub
1. Remove the O-ring (#117) from the brake spacer (#108). Remove the brake spacer and cam pilot(#109).
2. Carefully press the cam pilot (#109) from the brake spacer (#108).
3. Remove the brake actuator (#115) and thrust washer (#123) from the brake hub (#112).
4. Remove the brake hub (#112), preload spring (#120), cam plate (#107), brake disc (#113)and springs (#122).
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Removing the End Bearing
1. Remove the end bearing (#203) by removing the capscrews (#208, #207). Remove the O-ring (#216).
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