Ramsey Winch Company OWNERS MANUAL Front Mount Electric Winches

REP 6000 REP 8000 REP 9000

Layer of Cable Rated Line Pull Per Layer

Cumulative Cable Cap. Per Layer* 1/4" ( 6mm) dia. Cable

1 (lbs) (kg) (ft) (m) (lbs) (kg) (FPM) (MPM) 12V

Layer of Cable Rated Line Pull Per Layer

Cumulative Cable Cap. Per Layer* 5/16" (8mm) dia. Cable

1 (lbs) (kg) (ft) (m) (lbs) (kg) 12V 24V 12V 24V 12V 24V

Layer of Cable Rated Line Pull Per Layer

Cumulative Cable Cap. Per Layer* 5/16" (8mm) dia. Cable

1 (lbs) (kg) (ft) (m) (lbs) (kg) 12V 24V 12V 24V 12V 24V

6,000 5,000 4,400 3,800 2,720 2,260 1,990 1,720 20 6 NO 25 7.6 70 50 15 80 24 100 30

8,000 6,500 5,500 4,800 3,620 2,940 2,490 2,170 15 4 NO 36 30 10.9 9.1 87 43 40 12 70 21 95 28

9,000 7,300 6,200 5,400 4,070 3,300 2,800 2,440 15 4 NO 33 25 10 7.6 97 35 40 12 70 21 95 28

Line Pull First Layer Line Speed First Layer Amp Draw

1,000 3,000 5,000 6,000 1,350 2,260 2,720 16 4.8 240 10 3 370 8 2.4 440 21 6.4 155

LOAD 450

Line Pull First Layer (FPM) Line Speed First Layer (MPM)

2,000 4,000 6,000 8,000 1,810 2,720 3,620 12 13 3.6 3.9 258 125 8 10 2.4 3 320 160 5 8 1.5 2.4 405 200 15 17 4.5 5.2 168 93

Line Pull First Layer (FPM) Line Speed First Layer (MPM)

2,000 4,000 6,000 9,000 1,810 2,720 4,070 13 11 3.9 3.3 260 110 11 9 3.3 2.7 335 140 8 7 2.4 2.1 420 175 17 15 5.1 4.5 180 75

LOAD 900

LOAD 900

Amp Draw

Amp Draw

* Depends on cable being uniformly wound onto drum. Ramsey performance data is compiled from actual winch testing.

Congratulations
You have purchased the finest winch available in its service class. The REP 6000, REP 8000 and REP 9000 feature a highly efficient 3 stage planetary gear set. The REP 6000 transmits torque from a permanent magnet D.C. motor, while the REP 8000 and REP 9000 utilize a series wound D.C. motor. A safe positive clutch allows free spooling for quick cable deployment. An automatic load holding brake is designed to hold the full rated capacity of the winch. This winch 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. At the same time, there are easier and faster ways for getting the job done if certain precautions are taken first. 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.

Contents
Safety Precautions ..............................................2 Tips for Safe Operation ........................................2 Techniques of Operation ......................................3 Installation ........................................................4-8 Electrical Connections & Operations ....................6 Maintenance ........................................................9 Operating Instructions ..........................................9 Trouble Shooting Guide ......................................10 Winch Parts List ..........................................11-15 Warranty ..............................................Back Cover
Please Note: Ramsey REP6000, REP8000 and REP9000 Series winches are designed for front mount vehicle use. The winches are not designed for and should not be used in industrial applications (car haulers/carriers, wreckers, hoisting, etc.), and Ramsey does not warrant them to be suitable for such use. Ramsey makes a separate, complete line of winches for industrial/commercial use. Please contact the factory for further information.

CAUTION: Read and understand this manual before installation and operation of winch. See Safety Precautions.

Safety Precautions To Guard Against Possible Injury

A minimum of five wraps of cable around the drum barrel 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. B. Don't step over a cable, or near a cable under load. C. 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. E. Use a heavy rag or gloves to protect hands from burrs when handling winch cable. F. Apply blocks to wheels when vehicle is on an incline. G. 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. I. Keep the duration of your pulls as short as possible. If the motor becomes uncomfortably hot 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. J. 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. K. Note: Do not use winch in hoisting applications due to required hoist safety factors and features. L. 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
2

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.

Tips for Safe Operation

Don't underestimate the potential danger in winching operations. 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 innermost 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 practical, use a snatch block and double line arrangement (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.

For basic self-recovery, anchor to a tree or heavy rock. When anchoring to a tree, always use a tree trunk protector.

Stakes driven in solid earth and chained together make a good anchor point for self-recovery when no solid anchor point is available.

Winches equipped with cable guide fairleads can pull from several directions. Pull from an angle only to straighten up the vehicle-otherwise you can damage structural members or other parts of your vehicle and cause excess cable buildup on one end of the winch drum.

For a direct pull of 2000 lbs., hitch truck to a tree or solid anchor, and take out of gear.

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 recognize 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 vehicle or a load while your vehicle is anchored in a stationary position. The following sketches show you a few techniques. When pulling a heavy load, place a blanket, jacket or tarpaulin over the cable five or six feet from the hook. It will slow the snap back in the event of a broken cable. Also open the vehicle hood for additional protection.

For a solid anchor, bury a log with earth or sand or place it in a deep ravine.

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, nonindustrial 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. Note: If recommended 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 recommended that a Ramsey mounting channel be used in all nonRamsey 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 following 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.

REP 8000 12V & 24V/9000 12V When mounting winch, connect labeled motor leads coming from solenoid assembly to appropriately marked motor terminals. TIGHTEN NUTS ON MOTOR TERMINALS 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 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. TIGHTEN CLAMP SECURELY.

FIGURE 2
A A A

1 2

2 View A-A

FIGURE 1

REP 8000 24v REP 9000 12v

View A-A
REP 8000 12v

FIGURE 3

REP 9000 24V When mounting winch, connect labeled motor leads coming 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 bearing (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.

Hole for Solenoid Ground Wire Bolt

A 1

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 mounting 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 or better and torque to 34 ft. lbs.) Place end of drum cable through fairlead and attach cable hook. Use clevis pin and cotter pin (see FIGURE 5).

2 View A-A
REP 9000 24v

FIGURE 4

TO ENSURE PROPER ALIGNMENT OF THE ROLLER FAIRLEAD TO THE DRUM, POSITION SMALLER (7/16") SET OF HOLES AT BOTTOM FOR MOUNTING

ROLLER FAIRLEAD DETAIL A

FIGURE 5 5

FIGURE 6

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 connections are essential. Run the vehicle engine during winching operations to keep battery charged. The remote control switch is waterproof. It has push button stations on either side. It is designed this way to prevent quick winch reversals, which lead to solenoid failure. 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 appropriate "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.

REP-6000/REP-8000 12V & 24V/REP 9000 12V Electrical Connections Route red and black battery cables up to battery. CAUTION: BE SURE BATTERY CABLES ARE NOT DRAWN TAUT ACROSS ANY SURFACES WHICH COULD POSSIBLY 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. CAUTION: BE SURE BATTERY CABLES ARE NOT DRAWN TAUT ACROSS ANY SURFACES WHICH COULD POSSIBLY 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 owners manual. 1. Position winch as shown in Figure 6. Remove screws from tiebars. You may be able to 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 set on workbench. Remove the Retainer (item #37) by removing six capscrews (item #21) from Gear End Bearing (item 13). Once the retainer is removed, the Ring Gear (item #10), Cam Ring (item #36), and Locking Ring (item #34) can be lifted off the end bearing. Remove the six springs (item #38) from the end bearing.

FIGURE 9

FIGURE 8

5. Determine position shifter knob needs to be for your application. Note: Shifter knob cannot be positioned too low or it will interfere with the feet on the Gear End Bearing (see Range of Position in Figure 10). 6. To position the shifter knob, place locking ring in end bearing with stop post approximately 180 from where shifter knob needs to be positioned. Place cam ring over locking ring in proper position and confirm that shifter knob will move from engaged to disengaged position without interference. Mark position of stop post on end bearing.

FIGURE 10

7. 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 dont bend sideways. 8. 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. 9. 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 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, confirming that the slot in the bushing is aligned with the key in the end 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 fasten 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 performance or may cause a short. Clean all connections especially 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 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 " 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 revolution until the " 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 tab is located on the gear-housing end of the winch and operated as follows: 1. To disengage the clutch, move the clutch shifter tab to the "OUT" position. Wire rope may now be freespooled off the drum. 2. To engage the clutch, move the clutch shifter tab to the "IN" position. The winch is now ready for pulling.

Ramsey Electric Winches Troubleshooting Guide

CONDITION MOTOR RUNS IN ONLY ONE DIRECTION POSSIBLE CAUSE (1) Defective solenoid or stuck solenoid CORRECTION (1) Jar solenoid to free contacts. Check by applying 12 volts to coil terminal (it should make an audible click when energized) (2) Disengage winch clutch, remove remote control switch plug from the socket and jump pins at 8 and 4 oclock. Motor should run. Jump pins at 8 and 10 oclock. Motor should run (1) Cooling-off periods are essential to prevent overheating

(2) Defective remote control switch

MOTOR RUNS EXTREMELY HOT MOTOR RUNS, BUT WITH INSUFFICIENT POWER, OR WITH LOW LINE SPEED

(1) Long period of operation

(1) Insufficient battery

(1) Check battery terminal voltage under load. If 10 volts or less, replace or parallel another battery to it (2) Check battery cables for corrosion; clean and grease (3) Replace with larger capacity charging system (1) If clutch engaged but symptom still exists, it will be necessary to disassemble winch to determine cause and repair (1) Jar solenoid to free contacts. Check solenoid by applying 12 volts to coil terminal (it should make an audible click when energized) (2) Disengage winch clutch, remove remote control switch plug from the socket and jump pins at 8 and 4 oclock. Motor should run. Jump pins at 8 and 10 oclock. Motor should run. (3) If solenoids operate, check for voltage at armature post; replace motor (4) Tighten connections on bottom side of hood and on motor (1) Allow to drain and dry thoroughly, then run motor without load in short bursts to dry windings. (1) Check clutch operation according to nameplate. Make sure clutch shifter knob is fully at OUT position. (2) Check mounting to see that installation instructions on page 4 have been followed.

(2) Bad connection (3) Insufficient charging system MOTOR RUNS, BUT DRUM DOES NOT TURN MOTOR WILL NOT OPERATE (1) Clutch not engaged

(1) Defective solenoid or stuck solenoid

(2) Defective remote control switch

(3) Defective motor

(4) Loose connections MOTOR WATER DAMAGED (1) Submerged in water or water from high pressure car wash (1) Clutch not disengaged

CABLE DRUM WILL NOT FREESPOOL OR IS DIFFICULT TO FREESPOOL

(2) Winch not mounted squarely causing end bearing to bind drum

(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 (allen) 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.

10

REP 6000
Hawse Fairlead

Replacement Kit #251152 Included with: REP 6000 H

Roller Fairlead

Replacement Kit #251183 Included with: REP 6000 R

REP 6000 PARTS LIST

Item Qty. Parts No. No. 1 1 247009 2 1 247007 3 1 247008 4 1 251110 5 1 251228 6 1 278154 7 1 296181 8 1 332128 9 1 334143 10 1 334147 11 1 334154 12 1 338249 13 2 412056 14 1 412061 15 1 413018 16 4 414316 17 4 414829 18 1 414830 19 6 414861 Description Gear Carrier Assy.Input Gear Carrier AssyIntermediate Gear Carrier AssyOutput Switch Assy Cable Assembly-100 1/4 (6MM) Dia. Solenoid Assy Brake/Shaft Assy DrumCable GearRing GearIntermediate, Sun GearInput, Sun End Bearing BushingDrum BushingShaft CoverGear Housing Capscrew 3/816NCx1-1/4Lg.Hx.Hd.Gr.5,Z/P Capscrew 1/420NCx1 Lg. Soc. Button Hd. Capscrew 1/420NCx3/8 Lg. Soc. Button Hd. Capscrew 1/420NCx3/4 Lg. Flat Hd. Soc. NYLOK Item Qty. Parts No. No. 20 6 416273 21 4 418018 22 4 418035 23 4 418177 24 4 418181 25 1 424023 26 1 442207 27 1 444048 28 1 448071 29 2 448049 30 1 458109 31 1 470053 32 1 477002 33 1 477003 34 2 477004 35 1 479007 36 6 494077 37 3 518020 38 1 518027 Description Screw #632NCx3/8 Lg. Fil. Hd. Nut 1/420NC Hx. Reg. Elastic Stop Nut 3/816NC Hx. Reg. Z/P Lockwasher 3/8 ID Med. Sect. Plated WasherFlat 3/8 ID S.A.E., Plated Clamp Gasket GearOutput, Sun Cable Anchor Tie Bar Motor/End Bearing Assy. Roll Pin 1/8 Dia. x 3/8 Locking Ring Cam Ring RingHalf RetainerRing Gear Spring Thrust Washer Thrust Disc

11

REP 8000

Hawse Fairlead

Roller Fairlead

Replacement Kit #251152 Included with: REP 8000 H

Replacement Kit #251183 Included with: REP 8000 R

REP 8000 PARTS LIST

Item Qty. Parts No. No. 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16
17

Description Gear Carrier AssyIntermediate Gear Carrier AssyOutput Gear Carrier Assy.Input Switch Assy Cable Assembly-95 5/16 (8MM) Dia. Solenoid Assy - 12v Solenoid Ass'y - 24v Brake/Shaft Assy DrumCable GearRing GearIntermediate, Sun End Bearing BushingDrum BushingShaft CoverGear Housing Capscrew 3/816NCx1-1/4Lg.Hx.Hd.Gr.5,Z/P Capscrew 3/824NCx1/2 Hx. Hd. Z/P GR5 Capscrew 1/420NCx3/4 Lg. Soc. Button Hd. Capscrew 1/420NCx3/8 Lg. Soc. Button Hd. Capscrew 1/420NCx3/4 Lg. Flat Hd. Soc. NYLOK

Item Qty. Parts No. No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 6 4 5 4 1 1 1 1 1 2 1 1 1 1 1 2 1 6 3 1 2 416273 418035 418177 418181 424023 442207 444048 444097 448046 448049 296589 296591 470053 477002 477003 477004 479007 494077 518020 518027 518019

Description Screw #632NCx3/8 Lg. Fil. Hd. Nut 3/816NC Hx. Reg. Z/P Lockwasher 3/8 ID Med. Sect. Plated WasherFlat 3/8 ID S.A.E., Plated Clamp Gasket GearOutput, Sun GearInput, Sun Cable Anchor Tie Bar Motor - 12v Motor - 24v Roll Pin 1/8 Dia. x 3/8 Locking Ring Cam Ring RingHalf RetainerRing Gear Spring Thrust Washer Thrust Disc Thrust Washer

18 19 20

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 4 1 4 1 6

247005 247008 247024 251110 251118 278158 278192 296553 332128 334143 334145 338337 412056 412061 413018 414316 414370 414823 414830 414861

12

REP 9000

REP 9000 PARTS LIST

Item Qty. Parts No. No. 1 1 247009 2 1 247022 3 1 247023 4 1 278158 1 278096 5 1 251110 6 1 296181 1 296385 7 1 328138 8 1 332193 9 1 334154 10 1 334147 11 1 334170 12 1 334171 13 1 338337 14 1 338282 15 16 17 18 19 20 21 22 2 1 4 4 1 6 6 4 412056 412061 414316 414823 414830 414868 414861 418018 Description Gear Carrier Assy.Input Gear Carrier AssyIntermediate Gear Carrier AssyOutput Solenoid Assy12V Solenoid Assy24V Switch Assy Brake/Shaft Assy12V Brake/Shaft Assy24V CoverGear Housing DrumCable GearInput Sun GearIntermediate Sun GearOutput Sun GearRing, Output End Bearing End BearingMotor24V BushingDrum BushingShaft Capscrew 3/816NCx1-1/4Lg.Hx.Hd.Gr.5,Z/P Capscrew 1/420NCx3/4 Lg. Soc. Button Hd. Capscrew 1/420NCx3/8 Lg. Soc. Button Hd. Capscrew 1/420NCx2-1/2 Lg. Flat Hd. Soc. NYLOK Capscrew 1/420NCx3/4 Lg. Flat Hd. Soc. NYLOK Nut 1/420NC Hx. Elastic Stop Item Qty. Parts No. No. 23 4 418035 24 4 418040 25 5 418177 8 418177 26 5 418181 27 1 424023 28 1 442208 29 1 444077 30 1 448046 31 2 448049 32 1 450001 33 1 296570 1 458005 34 1 470053 35 1 477002 36 1 477003 37 2 477004 38 1 479007 39 6 494077 40 6 518020 41 1 518027 42 1 251118 43 1 289141 44 1 442219 45 1 414370 46 1 416212 Description Nut 3/816NC Hx. Reg. Z/P Nut 3/824NC Hx. Reg. Z/P Lockwasher 3/8 Med. Sect. Z/P 12V Lockwasher 3/8 Med. Sect. Z/P 24V WasherFlat 3/8 ID S.A.E. Z/P Clamp GasketCover GearRing, Input Cable Anchor Tie Bar Key24V. MotorElectric 12V MotorElectric 24V Roll Pin 1/8 Dia. x 3/8 Lg. Locking Ring Cam Ring RingHalf RetainerRing Gear Spring Thrust Washer Thrust Disc Cable Assembly CableGround Gasket Capscrew 3/8-24NF x 1/2 HX HD ZP GR5 Screw #10-24NC x 3/8 Lg Hx Soc Hd ZP

13

Solenoid Assembly Parts List REP 6000 278154REP 6000

Note: All unidentified hardware comes supplied with the solenoid.

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Qty. Req'd Part No. 2 289168 1 289090 1 289091 1 289169 2 364002 1 408102 1 413024 3 414053 7 416216 2 416227 6 418004 6 418014 4 418140 2 418141 3 418149 1 418165 3 418411 3 418514 1 430013 2 440071 2 440110 1 440111 1 289015 1 289141 1 482029

Description Wire AssemblyBlack 4 Ga. x 12 Lg. Wire AssemblyBlack 10 Ga. x 3 Lg Wire AssemblyBlack 16 Ga. x 1-1/2 Lg Wire AssemblyBlack 4 Ga. x 3-1/2 Lg StrapCopper Bracket CoverSolenoid Capscrew 1/420NCx1-1/4Lg.Hx.Hd. Z/P Screw #1024NCX 1/2 Lg. Rd. Hd. Z/P Screw #1024NCX 3/4 Lg. Truss Hd. Black NutHx. Reg. #1024NC Z/P NutHx. Reg 1/420NC Z/P Washer #10 SAE Flat Z/P Lockwasher #10 Med. Sect. Z/P Lockwasher 1/4 Med. Sect. Z/P Washer 5/16 Shakeproof External Teeth Nutsert #1024NC Spacer Connector FemaleMolded Terminal Tab Solenoid StrapCopper Wire AssemblyBattery Red 72 Wire AssemblyBattery Black 72 CoverFemale Connector

14

Solenoid Assembly Parts List REP 8000/9000 278158REP 8000/9000 12V 278192REP 8000 24V 278096REP 9000 24V

Note: All unidentified hardware comes supplied with the solenoid.

Item No. 1 2 3 4 5 6 7 8 9 11 12 13 14 16 17 18 20 21 22 23 24 25 26

Qty. Req'd 1 1 1 3 3 1 1 2 1 1 3 7 2 6 6 3 2 3 3 3 1 2 2 2 1 1

Part No. 289015 289091 289092 289171 289115 289208 289209 364002 408102 413024 414053 416216 416227 418004 418014 418140 418141 418149 418411 418514 430013 440071 440110 440114 440111 482029

Description Wire AssemblyBattery Red 72" Wire AssemblyBlack 16 Ga. x 1-1/2 Lg. Wire AssemblyBlack 6 Ga. x 3-1/2 Lg Wire AssemblyMotor LeadREP 8000 12V & 24V/REP 9000 12V Wire AssemblyMotor LeadREP 9000 24V Wire AssemblyGround--REP 8000 12V & 24V/REP 9000 12V Wire AssemblyGround--REP 9000 24V StrapCopper Bracket CoverSolenoid Capscrew 1/420NCx1-1/4Lg.Hx.Hd. Z/P Screw #1024NCX 1/2 Lg. Rd. Hd. Z/P Screw #1024NCX 3/4 Lg. Truss Hd. Black NutHx. Reg. #1024NC Z/P NutHx. Reg 1/420NC Z/P Washer #10 SAE Flat Z/P Lockwasher #10 Med. Sect. Z/P Lockwasher 1/4 Med. Sect. Z/P Nutsert #1024NC Spacer Connector FemaleMolded Terminal Tab SolenoidREP 8000/9000 12V SolenoidREP 8000/9000 24V StrapCopper CoverFemale Connector

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 manufactured 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 purchaser 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. Chrome finish warranted for one year against manufacturing defects. Cracking, scratching or corrosion cuased by winching not covered by warranty. 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. An optional extended 2-year limited warranty for all electrical components may be purchased. The obligation under 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 fitness for a particular purpose; 2. All warranties of merchantability; 3. All claims for consequential or incidental damages. There are no warranties 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 warranties 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 Companys 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 authorization 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 COMPANY P BOX 581510 TULSA, OKLAHOMA 74158-1510 USA .O. PHONE (918)438-2760 FAX (918)438-6888 http://www.ramsey.com
Printed in U.S.A. OM-914098-0805-M