Ramsey 130K User Manual

OPERATING, SERVICE AND

MAINTENANCE MANUAL

WILDCAT SERIES 130,000 LB

INDUSTRIAL

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF

WINCH. SEE WARNINGS!

WINCH

TABLE OF CONTENTS

WARRANTY INFORMATION ............................................................................................................... 1

SPECIFICATIONS ................................................................................................................................ 1

WARNINGS .......................................................................................................................................... 1

HYDRAULIC SYSTEM REQUIREMENTS ........................................................................................... 2

CABLE INSTALLATION ...................................................................................................................... 3

CLUTCH OPERATION ......................................................................................................................... 4

WINCH OPERATION ........................................................................................................................... 4

MAINTENANCE ................................................................................................................................... 4

LUBRICATION TABLE ........................................................................................................................ 5

TROUBLE SHOOTING GUIDE ............................................................................................................ 5

INSTRUCTIONS FOR DISASSEMBLY ................................................................................................ 6

CARRIER DISASSEMBLY AND ASSEMBLY ................................................................................... 14

HOSE HOOKUP ................................................................................................................................. 21

PARTS DRAWING ............................................................................................................................. 22

PARTS LIST ....................................................................................................................................... 23

AIR CYLINDER .................................................................................................................................. 24

DIMENSIONAL DRAWING ................................................................................................................ 25

LIMITED WARRANTY ........................................................................................................................ 26

RAMSEY HYDRAULIC PLANETARY WINCH MODEL WILDCAT 130K

PLEASE READ THIS MANUAL CAREFULLY

This manual contains useful ideas in obtaining the most efficient operation from your Ramsey Winch, and safety procedures one needs to know before operating a Ramsey Winch. Do not operate this winch until you have carefully read and understand the "WARNINGS" 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*

APPROXIMATE WEIGHT: 2200

WORKING PRESSURE: 2600 PSI

CABLE DIAMETER: 1.125 INCH

MAX FLOW: 60 GPM

LAYER

CABLE

1 50 15 130000 58960

2 110 33 106300 48210

3 180 54 90000 40820

4 265 80 78000 35380

5 360 109 68800 31200

6 465 141 61500 27890

* These specifications are based on recommended wire rope of 1.125” Extra Improved Plow Steel Cable and a

9.0 cu. in. / Rev. motor.

NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.

CABLE

CAPACITY

Ft m Lb Kg

LINE PULL

LOW SPEED

LBS

LINE SPEED

fpm mpm

4.8

5.8

6.6

7.6

8.5

9.7

HIGH SPEED

LINE PULL LINE SPEED

Kg fpm mpm

60000

49000

41500

36000

31700

28400

27210 34 10.3

22220 40 12.1

18820 47 14.2

16320 54 16.4

14370 61 18.5

12880 68 20.6

WARNINGS:

CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERATION. DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH. DO NOT DISENGAGE CLUTCH UNDER LOAD. 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 PEOPLE. A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.

CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD.

BAND BRAKE IS NOT TO BE USED TO HOLD LOAD.

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts, below, to properly match your hydraulic system to winch performance. The charts consist of:

(1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) line speed, first layer (FPM) vs. gallons per minute (GPM). Performance based on a motor displacement of 7.0 cubic inches/rev with 60 GPM maximum flow rate. Motor has (2) 1”-12 SAE straight thread o-ring ports.

Note: A motor spool (open center) directional control valve is required for brake operation.

MOTOR CASE DRAIN

MOTOR 2 SPEED

SAE -16 1" TUBING SIZE

12 VDC

PORT #5

SHIFT SOLENOID

COUNTER BALANCE

VALVE

COUNTER BALANCE/SPEED SELECTOR BLOCK

LOW PRESSURE LINE

BRAKE

PORT #1

PORT#3

SAE -16 1" TUBING SIZE

CLUTCH

AIR CONNECTIONS

HIGH PRESSURE LINE

PAYOUT

PAYIN

DIRECT LINE TO TANK

BAND BRAKE

3 POSITION

4 WAY VALVE

SYSTEM RELIEF

PUMP

CUSTOMER SUPPLIED

PERFORMANCE CHARTS

BASED ON 7.0 CU IN/REV MOTOR

CABLE INSTALLATION

1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of wire rope, opposite hook, with plastic or similar tape to prevent fraying.

2. Place taped end of cable into the hole on the drum flange and bend into the track on drum flange. Secure using supplied u-bolt #73 and (2) nuts.

3. Carefully run the winc h in the “reel-in” direction. Keeping tensio n on end of cable, spool all the cable onto the cable drum, taking care to form neatly wrapped layers.

4. After installing cable, band brake is used to prevent bird nesting while pulling out cable, when clutch is disengaged.

BEND INTO TRACK

AS SHOWN

INSERT END OF CABLE INTO HOLE AS SHOWN

CLUTCH OPERATION

WARNING: CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.

To engage clutch:

1. Move clutch control to engage the clutch.

2. Run the motor in the cable out direction until the drum begins to turn.

WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD.

To disengage clutch:

1. Run the winch in the "cable out" direction until the load is off the cable.

2. Move the clutch control to disengage the clutch. The cable may now be spooled off.

WINCH OPERATION

The best way to get acquainted with how your winch operates is to make test runs before you use it. Plan your test in advance. Remember, you hear your winch, as well as see it operate; 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 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.

MAINTENANCE

Adhering to the following maintenance schedule will keep your winch in top condition and performing as it should with a minimum of repair.

A. WEEKLY

1. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and

repair.

2. Check the pressure relief plug on the gear housing cover and the brake housing cover. Be sure they

are not plugged.

Lubricate cable with light oil.

4. Lubricate drum bushings with grease. It is necessary to remove cable to expose the grease zerks on drum. Use high quality lithium grease for best results.

5. Apply a high quality lithium grease to clutch spline. Apply band brake to control drum. Declutch drum and apply grease to spline between clutch and drum.

B. MONTHLY

Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are loose. Use grade 8 or better bolts.

2. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.

C. ANNUALLY

Drain the oil from the winch annually or more often if winch is used frequently.

2. Refill the winch to the oil level plug with all purpose GL-5 oil, (see page 5) for gear lube compatible with

your climate.

3. Inspect winch for damage and wear.

LUBRICATION TABLE

TempRangeF(C)

LubricantDescription*

80W140Synthetic ‐25(‐32) 125(52) 225(107) 75W90Synthetic ‐40(‐40) 115(46) 215(102) 80W90Conventional ‐20(‐29) 100(38) 180(82) 85W140Conventional 20(6) 120(50) 200(93)

Min

Ambient&

Operating

Max 

Ambient

Max 

Operating

*UseAPIGL‐5orEPlubricants.

TROUBLE SHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION

OIL LEAKS FROM WINCH

WINCH RUNS TOO SLOW

CABLE DRUM WILL NOT

FREESPOOL

1. Seals damaged or worn.

2. Too much oil.

3. Damaged o-rings.

4. Case drain not connected.

1. Low flow rate.

2. Hydraulic motor worn out.

1. Clutch not disengaged 1. Check operation. Refer to Clutch

1. Replace seal

2. Drain excess oil. Refer to page 6.

3. Replace o-rings.

4. Connect case drain.

1. Check flow rate. Refer to HYDRAULIC SYSTEMS performance chart on page 2.

2. Replace motor.

Operation on page 4.

BRAKE WLL NOT HOLD

BRAKE WILL NOT RELEASE

WINCH WILL NOT OPERATE AT HIGH SPEED

WINCH OPERATES ERRATICALLY ON INHAUL

1. Incorrect directional control valve. (cylinder spool, closed center).

2. Excessive hydraulic system back pressure.

3. Sprag clutch worn out.

1. Brake line disconnected or blocked 1. Repair brake line.

1. Shift solenoid not working. 1. Verify shift spool is energized.

1. Sprag hub is reversed. 1. Install sprag hub correctly.

1. Use only a motor spool (open center) directional control valve.

2. Reduce system back pressure to less than 100 psi.

3. Replace sprag clutch mechanism.

INSTRUCTIONS FOR DISASSEMBLY

1. Remove wire rope from drum.

2. Drain oil from winch by removing (2) plugs #63, removing the lower plug first.

3. When replacing lubricant, use 496 oz of applicable lube for your climate from table on page 5, adding 16 oz at #52 and the remaining at #64.

4. Remove (2) nuts #408b from air cylinder #408a. Air cylinder may now be removed. If needed, mounting bracket #401 may be removed by removing pin #404 from pin #405 and then sliding pin out of mounting bracket. Brake band #6 may be expanded over drum flange to barrel for easiest removal.

NOTE: BRAKE BAND FITS OVER DRUM FLANGE

201

208b

204

205

208a

5. Remove motor #53 from winch by first disconnecting hydraulic lines (see page 17), solenoid wires, and then remove (4) bolts #36. O-ring #55 may now be removed.

6. Remove brake cover #50 by removing (4) bolts #35. The cover is spring loaded, use care when removing. Remove o-ring #54 then springs #69 may be removed; residual oil may be present in the brake housing.

7. Remove piston #13 including o-rings and backup rings #56, #57, #58, and #59 by using a momentary puff of compressed air into the brake port located on top of the end bearing. Capture the piston by placing a shop rag over the opening prior to using air.

8. Remove the sprag brake hub assembly #5, (7) stator plates #14, (6) disc brakes #15, and the spacer #25. The sprag brake hub assembly #5 is not a serviceable part, if damaged a replacement assembly should be ordered.

+ 19 hidden pages