Ramsey Electronics 2000 Manuel utilisateur

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Ramsey

Winch

Company

OWNERS

MANUAI

Front

iViount

Electric

Winch

Model

2000

with

Hawse

Type

Falrleads*

Model

2001

with

Roller

Type

Fairleads*

Model

7901

with

Roller

Type

Fairlead*

V

/

)

Zi

I

'"Mk

^/UUiM

^

J

-

(y

'

Now

Equipped

with

RAM-LOK

clutch

MODEL

2000

with

Hawse

Type

Falrleads

MODEL

2001

with

Roller

Type

Fairlead

Congratulations

You

have

purchased

the

finest

winch

avail

able

in

its

service

class.

It

was

designed

and

manufactured

to

provide

you

with

the

utmost

in

fun

and

utility.

The

new

RAM-LOK

clutch

gives

you

easier

free

spooling

and

positive

clutch

engagement

for

greater

convenience.

As

with

any

device

that

com

bines

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

obtain

ing

the

most

efficient

operation

from

your

Ramsey

Winch

and

safety

procedures

you

need

to

know

before

beginning

use.

When

you

follow

our

guidel

ines

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

pull

ing

for

you.

Limited

Warranty

Ramsey

Winches

are

designed

and

built

to

ex

acting

specifications.

Great

care

and

skill

go

into

every

winch

we

make.

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

prob

lems

with

your

winch,

please

follow

instructions

for

prompt

service

on

all

warranty

claims.

Contents

Techniques

of

operation

2

Operating

instructions

3

Tips

for

safe

operation

3

Brief

list

for

uses

4

Suggestions

for

maintenance

of

your

winch

5

Troubleshooting

guide

5

Winch

parts

drawing

6

Winch

parts

list

7

Solenoid

switch

parts

drawing

8

'MODEL

2000/2001

12

Volt

MODEL

7901

12

Volt

MODEL

2002/2003

24

Volt

24

Volt

Available

Techniques

of

Operation

The

best

way

to

get

acquainted

with

how

your

winch

operates

is

to

make

a

few

test

runs

before

you

ac

tually

need

to

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.

Soon

you

will

gain

confidence

in

operating

your

winch

and

its

use

will

become

second

nature

with

you.

Your

winch

will

not

only

pull

you

up

or

ease

you

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

to

start

your

imagination

working.

r.

a

Winches

equipped

with

cable

guide

rollers

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.

Anchor

to

a

tree

or

a

heavy

rock.

A

direct

pull

of

2,000

lbs.

ailAf

_

V

Stakes

driven

in

solid

earth

and

chained

together

make

a

good

anchor

point.

Anchor

made

by

burying

a

log.

Bury

your

spare

tire

horizon

tally

with

an

adequate

covering

of

earth

or

sand.

Double

the

pull,

twice

the

time

to

pull

it.

For

a

4,000

lb.

pull,

hitch

truck

to

tree

or

other

solid

anchor.

Always

carry

a

spare

set

of

cable

clamps

and

hook

for

use

in

case

the

cable

breaks.

Never

install

less

than

two

cable

clamps

with

not

less

than

three

inches

separation.

Use

tfie

vefiicle

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

area

for

anchoring

possibilities

as

well

as

leverage

situations,

direction,

and

goal.

Operating

instructions

1.

To

spool

winch

cable

on

and

off

drum,

operate

thumbswitch

in

control

switch

handle.

2.

The

RAM-LOK

semi-automatic

clutch

provides

free

spooling

and

clutch

engagement

with

the

cable

drum.

The

spring-loaded

RAM-LOK

clutch

Is

engaged

by

pull

ing

clutch

handle

outward,

rotating

90°

clockwise

and

releasing.

Spring

tension

forces

the

clutch

jaws

into

position

as

the

clutch

starts

to

turn

and

complete

engagement

when

the

clutch

jaws

and

cable

drum

jaws

are

properly

aligned

or

posi

tioned.

To

disengage

pull

clutch

handle

outward

rotate

90°

counter-clockwise

to

lock

clutch

at

disen

gaged

position.

Do

not

engage

or

disengage

clutch

when

power

is

being

transmitted

to

winch.

3.

Hidden

Winch

Kits

utilize

a

remote

cable

control

for

shifting

the

RAM-LOK

clutch.

To

disengage

clutch

pull

"T"

handle

on

control

cable

outward

and

rotate

clockwise

until

tight.

(Clutch

cable

control

has

built-in

locking

device.)

4.

Before

putting

winch

into

service,

perform

three

or

four

winching

operations

under

light

loads

to

seat

worm

gear

to

wormshaft

and

break-in

components.

5.

Be

sure

load

is

directly

in

front

of

winch.

Note:

This

is

the

best

position

for

pulling

and

also

for

even-layering

of

the

cable

on

the

drum.

Pulling

against

either

side

roller

causes

uneven

layering

and

limits

drum

capacity.

6.

Install

heavy-duty

battery

in

vehicle

for

heavy

or

long

pulls.

Add

second

battery

to

system

for

additional

power

if

desired.

Be

sure

batteries

are

connected

in

parallel;

that

is,

positive

post

to

positive

and

negative

post

to

negative.

7.

Warning:

Goods

are

not

intended

for

use

in

the

lifting

or

moving

of

persons.

The

winches

described

herein

are

neither

designed

for

use

application

to

equipment

used

in

the

lifting

or

moving

of

persons.

Any

such

use

shall

be

considered

to

be

improper

and

the

seller

shall

not

be

responsible

for

any

claims

arising

therefrom.

This

sale

is

made

on

the

express

understanding

that

there

is

no

implied

warranty

that

the

goods

shall

be

fit

for

the

purpose

of

lifting

or

moving

persons

or

other

improper

use

and

there

is

no

implied

warranty

or

merchantability

for

such

purposes.

Performance'

Line

Pull

(Lbs.)

0

2,000

4,000

6,000

8,000

Line

Speed

(F.P.M.)

15

7.5

5.5

4

3

Specifications

Rated

Line

Pull

8,000

lbs.

Total

Gear

Reduction

360

to

1

Weight

(Winch

only):

Model

2000

73

lbs.

Model

2001

73

lbs.

Model

7901

65

lbs.

Shipping

Weight

Complete:

Model

2000

112

lbs.

Model

2001

114

lbs.

Model

7901.

...

165

lbs.

Layer

of

Gable

1

2

3

4

5

6

Rated

Line

Pull

Per

Layer

(Lbs).

8,000

6,900

6,100

5,400

4,900

4,500

Cable

Capacity

Per

Layer

(Ft.)

Model

2000/2001

22

44

69

97

128

162

Model

7901

16

33

52

73

97

122

*

Based

on

the

first

layer

of

cable

on

drum.

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.

Don't

worry

about

even

spooling

while

pulling

a

load

unless

there

is

a

cable

pile-up

at

one

end.

After

the

job

is

done

you

can

respool

for

a

neat

lay

of

the

cable.

When

you're

pulling

a

heavy

load

where

there

Is

even

a

remote

chance

for

cable

failure,

place

a

blanket,

jacket

or

tarpaulin

over

the

cable

about

six

yards

behind

the

hook.

It

acts

as

a

parachute

..

.

slows

the

snap-back

of

a

broken

cable

and

could

save

you

from

serious

injury.

Don't

leave

your

winch

in

gear.

Circumstances

can

occur

that

could

cause

heavy

damage

to

your

vehicle,

if

by

some

rare

accident

the

winch

started

operating,

causing

the

hook

to

catch

and

pull

against

a

part

of

the

vehicle

or

winch.

Respect

for

your

winch

and

vehicle

as

well

as

com

mon

sense

in

their

operation

will

reward

you

with

safe

and

dependable

work

from

them.

Don't

take

chances;

make

sure

in

every

hook-up

that

you

are

in

command.

To

guard

against

possible

injury...

A.

Keep

yourself

and

others

a

safe

distance

to

the

side

of

the

cable

when

pulling.

B.

Don't

step

over

a

cable,

or

near

a

cable

In

tension.

C.

Don't

move

the

vehicle

to

pull

a

load

on

the

winch

cable.

This

could

result

in

cable

breakage.

D.

Use

a

heavy

rag

or

gloves

to

protect

hands

from

burrs

when

handling

winch

line.

Do

not

use

hands

to

guide

a

winch

line

that

is

under

tension.

E.

Apply

blocks

to

wheels

when

vehicle

is

on

an

incline.

F.

Stay

out

of

and

safely

away

from

a

vehicle

in

a

dangerous

spot.

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.

Winches

are

not

to

be

used

to

lift,

support

or

other

wise

transport

personnel.

J.

A

minimum

of

five

wraps

of

cable

around

the

drum

barrel

is

necessary

to

hold

the

rated

load.

Brief

List

of

Uses

When

the

going

gets

tricky

and

you

want

to

get

there

safely,

the

Ramsey

winch

Is

a

fine

companion

to

have

on

your

journey.

A

winch

can

provide

more

vacation

fun

as

well

as

year-around

utility.

Pull

yourself

out

of

a

snowbank,

mud

hole,

or

up

a

steep

hill.

Sometimes

the

shortest

route

to

your

destina

tion

calls

for

the

use

of

a

reliable

winch

.

.

.

a

Ramsey.

Launching

and

loading

marine

equipment

Is

easier

and

safer

with

a

good

winch

when

you're

In

the

tall

and

uncut.

If

your

profession

or

sport

takes

you

con

stantly

Into

off-road

territory,

a

winch

should

be

part

of

your

gear

at

all

times.

For

mobile

emergency

uses

of

all

kinds.

A

winch

offers

power

to

get

you

and

others

out

of

trouble

quickly

and

safely.

Suggestions

for

Maintenance

of

Your

Winch

Spool

the

cable

properly

on

the

drum

when

storing

between

each

usage.

Check

the

oi

l

level

in

the

gear

box

every

six

months.

At

the

same

time,

check

eiectricai

connections

and

mounting

bolts

—

tighten

if

necessary.

Be

sure

the

winch

has

pienty

of

battery

power

availabie.

The

minimum

ampere-hour

rating

of

the

vehicie

battery

should

be

70,

and

used

with

at

ieast

a

40

amp.

alternator.

Replace

oil

annually

or

more

often

ifwincl>:-is.used

frequently.

We

suggest

all

purpo^

SAE

TAOWr

worm

EP

90

weight

t\Vi

90

weight

oii

gear

box

and

SAE

20

for

spur

gear

box.

Apply

cup

grease

to

lube

fitting

at

top

of

ciutch

housing.

Check

periodicaiiy

to

determine

if

ciutch

operates

freeiy.

If

not,

lubricate.

Should

winch

be

submerged

for

a

brief

period,

drain

oil,

flush

and

replace

oil

in

gear

boxes.

Place

oil

in

motor

pots

and

ail

grease

zerks.

On

hidden

winches

check

periodicaiiy

to

determine

that

the

ciutch

cable

control

operates

freeiy.

If

not,

lubricate,

if

winch

is

not

to

be

used

for

an

extended

period,

disconnect

winch

battery

cable

from

the

battery.

For

best

results,

use

only

factory

certified

replace

ment

parts.

Ramsey

Electric

Winches

Trouble

Shooting

Guide

t'

CON

cond

ition

MOTOR

RUNS

IN

ONE

DIRECTION

ONLY

MOTOR

RUNS

EXTREMELY

HOT

MOTOR

RUNS,

BUT

WITH

INSUFFICIENT

POWER,

OR

WITH

LOW

LINE

SPEED

MOTOR

RUNS,

BUT

DRUM

DOES

NOT

TURN

MOTOR

WILL

NOT

OPERATE

MOTOR

WATER

DAMAGED

CLUTCH

INOPERATIVE

OR

BINDS

UP

CLUTCH

SPRING

DOES

NOT

OPERATE

CLUTCH

DOES

NOT

LOCK

AT

DISENGAGED

POSITION

REMOTE

CABLE

CONTROLLED

CLUTCH

DOES

NOT

LOCK

IN

DISENGAGED

POSITION

OIL

LEAKS

FROM

HOUSING

POSSIBLE

CAUSE

(1)

Defective

solenoid

or

stuck

solenoid

(2)

Defective

switcfi

(3)

Broken

wire

or

bad

connection

(1)

Long

period

of

operation

(2)

Insufficient

battery

(3)

Cable

from

battery

to

wlncti

too

small

(4)

Bad

connection

(5)

Insufficient

cfiarging

system

(1)

Ciutcti

not

engaged

(2)

Stieared

drum

stiaft

key

(3)

Stripped

bronze

gear

(4)

Parted

sfiaft

(1)

Defective

solenoid

or

stuck

solenoid

(2)

Defective

switcti

(3)

Defective

motor

(4)

Loose

connections

(1)

Submerged

in

water

CORRECTION

(1)

Jar

solenoid

to

free

contacts.

Cfieck

by

applying

12

volts

to

coll

terminal

(It

sftould

make

an

audible

click

when

energized).

(2)

Disengage

winch

ciutch

or

remove

armature

lead.

Remove

switch

plug

from hood.

Raise

connector

cover

on

hood

and

with

a

screw

driver,

short

the bottom

two

pins.

Solenoid

should

click.

Short

the

two

left

hand

pins.

The

other

solenoid

should

operate.

If

both

solenoids

operate

check

for

a

broken

wire

In

switch

cable.

Check

for

loose

connection

on

switch

and

switch

connector.

Gooling-off

periods

are

essential

to

prevent

over-heating.

Check

battery

terminal

voltage

under

load.

If

10

volts

or

less,

replace

or

parallel

another

battery

to

it.

Check

battery

to

ground

(chassis)

cable.

Must

be

No.

2

or

larger.

Check

battery

cables

for

corrosion;

clean

and

grease.

Replace

with

larger

capacity

charging

system.

(3)

(1)

(2)

(3)

(4)

(5)

(1)

If

ciutch

engaged

but

symptom

still

exists,

it

will

be

necessary

to

disassemble

winch

to

determine

cause

and

repair.

(1)

Dry

or

rusted

shaft

(2)

Dog

point

setscrew

too

tight

(3)

Bent

yoke

(4)

Keys

pulled

out

of

shape

by

over

load

(1)

Broken

spring

(1)

Set

screw

loose

or

worn

(1)

Failure

to

properly

secure

remote

cable

(1)

New

seal

(2)

Seal

damaged

or

worn

(3)

Too

much

oil

(4)

Damaged

gasket

(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

or

remove

armature

lead.

Re

move

switch

plug

from

hood.

Raise

connector

cover

on

hood

and

with

a

screw

driver,

short

the

bottom

two

pins.

Solenoid

should

click.

Short

the

two

left

pins.

The

other

solenoid

should

operate.

If

both

solenoids

operate,

check

for

a

broken

wire

in

switch

cable.

if

solenoids

operate,

check

for

voltage

at

armature

post;

replace

motor.

Tighten

connections

on

bottom

side

of

hood

and

on

motor.

(3)

(4)

(1)

Allow

to

drain

and

dry

thoroughly,

then

run

motor

with

out

load

in

short

bursts

to

dry

windings.

(1)

(2)

(3)

(4)

Clean

and

lubricate.

Remove

rubber

plug

from

ciutch

housing

and

rotate

set-

screw

outward

until

ciutch

operates

smoothly.

Replace

rubber

plug.

Replace

yoke

or

shifter

assembly.

'

If

drum

shaft's

keyways

are

rounded

or

damaged

replace

shaft

and

keys.

If

not,

file

off

burrs

and

replace

keys.

(1)

Replace.

(1)

Remove

rubber

plug

from

clutch

housing,

tighten

set-

screw

or

replace.

Replace

plug.

(1)

See

individual

mounting

kit

Instructions

for

proper

adaptation

of

cable

to

ciutch

assembly.

See

paragraph

(3)

in

Operating

Instructions,

Page

3

Owner's

Manual.

(1)

New

seals

sometimes

leak

until

seated

to

shaft.

(2)

Replace.

(3)

Drain

excess

oil

per

lubrication

Instructions.

(4)

Replace.

NOT

INCLUDED

WITH

7901

KIT

WINCH

@1

m

.,

-

SOLENOID

ASS'Y.

^

7/

278027

(12

VOLTSHfi^

/

278028

(24

VOLTSV^

NOTE:

ALL

ITEMS

DESIGNATED

WITH

A

TRIANGLE

A

ARE

SUB-ASSEMBLIES

AND

CAN

BE

PURCHASED

ASSEMBLED

-

BY

SUB-ASS'V,

NO.

-

OR

SEPARATELY

BY

PART

NO.

V

SWITCH

ASS'Y.

_

282001

—(4)

SEE

BACK

PAGE

FOR

COMPONENT

BREAKDOWN

Winch

Parts

List

Sub

Assembly

Parts

Item

Qty.

1

Item

Qty.

No.

Req'd

Part

No.

Description

No.

Req'd

Part

No.

1

1

276028

Shifter

Ass'y.

38

6

414110

2

1

278027

Soienoid

Ass'y.

(12V)

39

2

414310

3

1

278028

Solenoid

Ass'y.

(24V)

40

4

414842

4

282001

Switch

Ass'y.

41

2

414851

5

i

1

289015

Battery

Cabie

42

1

416029

6

316083

Bearing

Cap

43

1

416036

7

324134

Jaw

Clutch

44

1

416057

8

1

328105

Cover

—

W.G.

45

3

418039

9

1

328106

Cover

—

S.G.

46

5

418154

10

1

332002

Cable

Drum

2000/2001

47

5

418177

11

1

332079

Cable

Drum

7901

48

2

438001

12

1

334001

Idler

Gear

49

1

442001

13

334003

Spur

Gear

50

2

442002

14

1

334005

Gear

R.H.

46:1

51

1

442003

15

1

334129

Pinion

Gear

52

1

450005

16

336010

Handie

53

1

456001

17

338017

Gear

Housing

54

2

456008

18

1

338203

Spur

Gear

Housing

55

1

458001

19

1

338208

Clutch

Housing

56

1

458005

20

1

340001

Gear

Hub

57

1

462015

21

1

342033

Key

58

2

468002

22

342075

Key

59

3

468011

23

1

342186

Key

60

1

468018

24

342084

Key

61

2

470001

25

1

356901

Shaft

62

1

470033

26

1

357406

Drum

Shaft

2000/2001

63

1

472012

27

1

357405

Drum

Shaft

7901

64

1

482013

28

1

1

364029

Strap

65

1

486009

29

1

366016

Spacer

66

1

486017

30

1

368162

I

Worm

R.H.

46:1

67

1

486023

31

1

402002

Bearing

68

1

490003

32

3

412038

Bushing

69

2

494002

33

1

412039

Bushing

70

1

494053

34

4

412040

Bushing

71

3

518002

35

3

414049

Capscrew

72

1

524116

36

7

414059

Capscrew

73

1

524117

37

12

414060

Capscrew

Description

Capscrew

Capscrew

Capscrew

Capscrew

Setscrew

Setscrew

Setscrew

Nut

Washer

Lockwasher

Drag

Brake

Gasket

Gasket

Gasket

Key

—

Woodruff

Grease

Fitting

Relief

Fitting

Motor

(12V)

Motor

(24V)

0-Ring

Reducer

Pipe

Plug

Pipe

Plug

Dowel!

Pin

Spiral

Pin

Plug

Grommet

Oil

Seal

Oil

Seal

Oil

Seal

Snap

Ring

Spring

Spring

Thrust

Washer

Cable

&

Hook

7901

Cable

&

Hook

2000/2001

Item

Qty.

No.

Req'd

Part

No.

Description

A

1

222040

Ciutch

Housing

Ass'y.

A

1

228059

Gear

Housing

Cover

Ass'y.

A

1

228060

Spur

Gr.

Hsg.

Cover

Ass'y.

A

1

234080

Drum

Ass'y.

7901

A

1

234119

Drum

Assy.

2000/2001

A

1

248041

Gear

Housing

Assy.

Item

Qty.

No.

Req'd

Part

No.

Description

A

1

248042

Spur

Gear

Housing

Ass'y.

A

1

250149

Sp.

Gr.

&

Pin.

Shaft

Ass'y.

A

1

250329

Gear

&

Shaft

Ass'y.

7901

A

1

250330

Gr.

&

Sh.

Ass'y.

2000/2001

A

1

262005

Motor

Ass'y:

(12V)

A

1

262007

Motor

Ass'y.

(24V)

Roller

Type

Fairlead

274016*

274014**

'Included

when

ordering

Model

2001

'Included

when

ordering

Model

7901

Roller

Guide

Parts

Item

Qty.

2001

7901

No.

Req'd

Part

No.

Part

No.

Description

1

1

333019

333017

Roiier

Rrame

2

2

346035

346032

Pin-Rolier,

Long

3

2

346036 346036

Pin-Roller,

Short

4

2

354028

354026

Roller,

Long

5

2

354029

354029

Roller,

Short

6

4

418404

418404

Pal

Nuts

7

2

470032

470032

Spiral

Pins

.094

Dia.

x1

Ig.

Hawse

Type

Fairlead

395063*

'Included

when

ordering

Model

2000

When

ordering

parts

be

sure

they

are

Ramsey

Certified

Parts

Solenoid

Assembly

Parts

278027

—

12V

278028

—

24V

ARE

PART

OF

SOLENOID

2

LETTERS

A,

B,C,D,

INDICATES

A

CONNECTION

OF

CENTER

LINES

WITH

CORROSPONDING

LETTER

AND

SHOULD

BE

ASSEMBLED

ACCORDING

TO

CENTER

LINES

^

^

)

BLUE

BLACK

Item

Qty.

No.

Req'd

Part

No.

Description

1

1

226007

Connector

Ass'y.

2

1

280001

Strap

Gapscrew

Ass'y.

3

3

289013

Wire

Ass'y.

4

1

289069

Wire

Ass'y.

5

2

364001

Strap

6

2

364002

Strap

7

1

408035

Bracket

—

Sol.

8

2

416216

Screw

#10-24

x

Vz

Ig.

9

2

416256

Screw

—

Metal

#10

10

2

418004

Nut

#10-24

11

1

418022

Nut

%-18NC

12

2

418141

Lockwasher

#10

Med.

Sect.

13

1

418163

'

Lockwasher

?(j-Med.

Sect.

14

1

418164

Lockwasher

Int.

Tooth

15

1

418165

Lockwasher

Ext.

Tooth

16

1

419402

Nut

—

Jam

17

2

440003

Solenoid

—

12V

18

2

440017

Solenoid

—

24V

19

2

440071

Terminal

—Tab

20

1

472011

Cover

21

2

518013

Fiber

Washer

282001

Switch

Assembly

Parts

Item

No.

Part

No.

Description

289011

Wire

Ass'y.

10

ft.

long

416189

Screw

418003

Nut

430001

Male

Connector

472001

Handle

504009

Toggle

Switch

SCHEMA!

IC

"X

Ramsey

Winch

Company

Post

Office

Box

15829

'Tulsa,Oklahoma

74112*Telephone:

(918)

835-1521

Mounting

Kit

No.

2746

Instaiiation

Instructions

Chevrolet

Blazer,

V2,

%

&

1

Ton

Pickups

GMC

Jimmy,

V2,

%

&

1

Ton

Pickups

Ramsey

Model

2000

and

2001*

Front

Mount

Winch

liwlSilHilii

""HI''

r

"iFr'yfirn'nnf

iini

ii'"'iii'

"inS"

♦A.-.-

—

-

vA'*

'Sfft.Jt!.*'.

4

♦

■

)

•MODEL

2000/2001

12

Volt

MODEL

2002/2003

24

Volt

.

\

Installation

Instructions

A.

Remove

Vehicle

Bumper

|

1.

Save

bumper

hardware

for

re-installation

of

vehicle

bumper.

B.

Mounting

Kit

to

Winch

Assembly

1.

Remove

shipping

strap.

2.

Attach

Back-Bar

(Item

#10)

to

wihch

assembly

using

(3)

3/8-16NCx

1

Hx.

Hd.

capscrewb

with

iockwashers

and

(1)

%-16NC

x

%

Hx.

Soc.

Hd.

capscrews.

Tighten

all

bolts

to

proper

torque

value.

(See

Torque

Value

chart)

3.

Attach

front

mounting

angle

(Item

*8)

to

winch

as

sembly

using

(3)

%-16NC

x

1

Hx.

Hd.

capscrews

and

(1)

%-16NC

x

%

Hx.

Hd.

capscrews

all

with

Iockwashers.

Tighten

all

bolts

to

proper

torque

value.

(See

Torque

Value

Chart)

4.

Attach

roller

assembly

(included

with

Model

2001

winch)

to

top

side

of

front

mounting

angle

using

(2)

%-16NC

X

IVi

Hx.

Hd.

capscrews,

Iockwashers

and

nuts

and

(2)

%-16NC

x

1

Hx.

Hd.

capscrews

with

Iockwashers.

See

diagram,

tighten

all

bolts

to

proper

torque

value.

(See

Torque

Value

Chart)

5.

Bolt

brackets

(Item

#11

and

Item

#6)

to

Inside

of

ve

hicle's

right

side

rail

with

(4)

y2-13NC

x

iy2

Hx.

Hd.

capscrews.

Repeat

above

procedure

to

left

side

rail,

using

brackets

(Item

#12

arid

Item

#7).

6.

Before

lifting

kit

and

winch

assembly,

the

rubber

plug

must

be

removed

from

clutch

housing

to

allow

removal

of

alien

Hd.

setscrew.

Replace

plug

after

setscrew's

removal.

Remove

spiral

pin

(existing

pin)

from

clutch

handle.

Discard

handle

and

re-use

pin

to

attach

clevis

(Item

#13)

to

shifter

shaft

of

winch

assembly.

Bend

the

lip

of

the

female

electrical

connector

cover

in

the

solenoid

cover,

at

gear

housing

end

of

winch,

until

it

is

at

a

90°

angle

to

the

face

of

the

connector

cover.

Two

holes

rS%^

to

be

drilled

thru

vehicle's

left

side

rail;

(1)

%

(.344)

Dia.

hole

and

(1)

%

(.281)

hole.

See

diagram

—

View

"A"

for

approximate

location

of

holes.

After

holes

have

been

drilled,

attach

-angle

bracket

(Item

#9)

to

outside

of

frame

at

Hi

hole

using

yr-20NC

X

1

Hx.

Hd.

capscrew.

7.

Raise

winch

with

Back-Bar,

front

angle

with

roller

frame

attached,

between

right

and

left

side

mounting'

brackets.

Fasten

front

angle

to

front

side

of

mount

ing

brackets

(Items

#6

and

#7)

with

(1)

y2-13NC

x

^V4

(each

side)

use

Iockwashers

and

nuts.

Do

not

tighten

bolts.

Attach

Back-Bar

to

rear

mounting

brackets

(Items

#11

and

#12)

with

(2)

y2-13NC

x

11/2

Hx.

Hd.

cap-

screw

(each

side)

use

Iockwashers

and

nuts.

Level

winch

and

frame.

Tighten

all

bolts

to

proper

torque

value.

(See

Torque

Value

Chart)

Attach

brackets

(Items

#4

and

#5)

to

top

of

front

Torque

Value

Chart

Size

1/4-20

3/8-16

7/16-14

1/2-13

1/2-20

5/8-11

3/4-10

Torque

Ft.

Lbs.

5

18

28

39

41

83

105

Nm

6.7

24.4

37.9

52.8

55.5

112.5

142.3

mounting

angle

(Item

#8)

and

front

side

of

mounting

brackets

(Iterns

#6

and

#7)

with

y2-13NG

x

1%

Hx.

Hd.

capscrews,

use

Iockwashers

and

nuts.

See

dia

gram

—

Tighten

all

bolts

securely.

8.

Place

cable

thru

%

Dia.

hole

in

frame.

Place

cable

wire

thru

clevis

(Item

#13)

and

thru

swivel

(Item

#3)

and

secure.

(Be

sure

that

cable,

pushed

In

as

far

as

possible,

has

no

sharp

bends

and

clutch

Is

fully

engaged

be

fore

tightening

swivel

assembly.

After

swivel

has

been

tightened

bend

end

of

cable

90°,

so

swivel

will

not

slip

off

of

cable

during

operations.)

Secure

cable

housing

between

bracket

(Item

#9)

and

clip

(Item

#15)

using

y4-20NC

x

1

Hx.

Hd.

capscrews,

Iock

washers

and

nuts.

To

dis-engage

clutch

pull

cable

control

handle

out

and

rotate

clockwise

to

lock

clutch

at

dis-engaged

position.

C.

Bumper

Installation

1.

Connector

assemblies

(Item

#1

and

Item

#2)

are

provided

to

allow

for

a

more

convenient

location

for

the

female

connector

(Item

#1)

for

hand

control

switch.

Location

should

be

determined

and

holes

drilled

before

bumper

is

re-installed.

2.

Cut

bumper

as

shown

In

View

"B".

(License

plate

bracket

will

need

to

be

relocated

if

front

license

plate

is

required.)

3.

One

y2"

Dia.

(slotted)

hole

is

required

on

top

flange

of

bumper,

L.

H.

side,

for

cable

mounting./See

dia

gram

for

hole

location)

4.

Remount

vehicle

bumper,

using

existing

vehicl^^

hardware,

to

top

portion

of

frame?

To

attach

low^^^

portion

of

bumper

to

vehicle

(2)

y2-13NC

x

3

Lg.

capscrews,

Iockwashers

and

nuts

are

required.

Align

bumper

braces

and

bolt

securely

to

frame.

Tighten

all

bolts

to

proper

tor<fbe

value.

(See

Torque

Value

Chart)

5.

Take

male

connector

assembly

(Item

#2)

and

place

it

thru

designated

hole

In

bumper

and

plug

into

fe

male

connector

on

black

solenoid

cover

of

winch

assembly.

Fasten

female

connector

(Item

#1)

to

outside

of

bumper

using.

(2)

#10-24NC

x

Vs

Lg.

slotted

Hd.

screw.

Tighten

securely.

6.

Place

handle

end

of

cable

in

slotted

hole

in

bum

per

and

secure.

□.Battery

Cable

and

Remote

Switch

1.

Connect

battery

cable

to

winch.

2.

Route

cable

between

grill

and

vehicle

crossmember

up

to

the

posltivd'"post

of

battery.

(Be

sure

battery

cable

Is

not

on

any

sharp

edges.)

Y

3.

Plug

remote

switch

into

receptacle

on

winch.

^

4.

Run

winch

forward

and

reverse

to

check

connec

tions.

\

E.

Winch

Cable

1.

Unwind

cable

by

rolling

It

along

floor.

2.

Place

end

of

cable,

opposite

hook,

through

falrlead

and

into

hole

In

winch

drum.

3.

Secure

cable

with

setscrew.

4.

Wind

cable,

using

winch

power,

onto

drum

In

evei

layers.

(Refer

to

your

winch

owner's

manual

for

safe

operation.)

NOTE:

RIGHT

AND

LEFT

HAND

DIRECTIONS

AS

IF

SEATED

BEHIND

STEERING

WHEEL