Ramsey HD-P10000 User Manual

OPERATING, SERVICE AND

MAINTENANCE MANUAL

MODEL HD-P10000

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

WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

HYDRAULIC SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TYPICAL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

OVERHAUL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15

PARTS LIST AND PARTS DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-19

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BACK COVER

PLEASE READ THIS MANUAL CAREFULLY

This manual contains useful ideas for 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 "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*

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 P ul l (lbs.)

………………………………………

10,000

(Kg.)

………………………………………

4,530

Gear Reduct i on 5.1: 1

HD-P10000 STD 87 lbs . (39. 5 Kg) HD-P10000 "Y " 82 lbs . (37. 2 Kg)

1234 lbs. 10,000 8,300 7,100 6200 Kg. 4,530 3,760 3,220 2810

ft.205080115 m 6 15 24 35 ft.15305575 m491622 FPM32384451 MPM 9.8 11.6 13.4 15.5

……………………………………………..

Wei ght (wit hout cable)

* These specificat i ons are based on rec om m ended wire rope of 7/16" (11m m ) E IPS c abl e and a 24. 9 cu. i n./Rev. mot or.

LAYER OF CABLE

*Rated li ne pul l per layer

HD-P10000 (STD. DRUM )

* Line S peed (at 15 GPM )

HD-P10000 ("Y " DRUM)

* Cable Capaci ty per Lay er

WINCH MOUNTING

ESSENTIAL MOUNTING INSTRUCTIONS TO MAINTAIN ALIGNMENT OF PLANETARY WINCH COMPONENTS:

It is most important that this winch be mounted securely so that the three major sections (the motor end, the cable drum, and the gear housing end) are properly aligned. Excessive bushing wear and difficulty in freespooling are usually symptoms of misalignment.

In the as-installed condition, if the winch is mid-mounted, then at least one tie-plate must be attached to the mounting feet at the bottom of the winch to maintain alignment. If the winch is foot mounted then at least one tie-plate must remain mounted at midpoint of winch to maintain alignment. It is always preferred to used BOTH tie-plates in the final installed configuration.

Angle Mounting Kit, P/N 251006 (for Std. Drum) or 251007 (for “Y” drum), is recommended for maximum ease in mounting the winch. The angle kit will allow the winch to be mounted in upright or midmount applications and will meet the criteria of serving as a solid and true mounting surface.

When mounting the winch with other than the recommended Ramsey Angle Kit, the mounting hole patterns described in the Dimensional drawings on pages 14-15 should be used. The mounting surface must be flat within .015 inch and sufficiently stiff to resist flexing. If a steel plate is used for foot mounting, it should be .750 inch thick. For this mounting application eight (8) 1/2-13NC x 1-1/2” long grade 5 capscrews with lockwashers will be needed to mount winch. Capscrews should be tightened to 55 ft-lb (75 Nm) torque.

NOTE: If angles or a steel plate are used in mounting winch, tie-plates provided with winch are to be attached to the remaining mounting pads, whether they be side or foot.

* CAUTION: If longer bolts (minimum grade 5) are substituted to mount winch or to mount a roller guide at the side mount pads, bolt length must be such as to allow a minimum of .50 inch thread length engagement in the tapped holes in side of each end bearing. Refer to pages 14-15. Use of excessive length bolts will damage the winch and prevent freespool of the drum. Torque bolts to 55 ft-lbs. (75 Nm).

MID MOUNT

FOOT MOUNT

SEE BOLT LENGTH CAUTION BELOW *

TIEPLATE AT FOOT (BASE) LOCATION

TIEPLATE AT SIDE LOCATION

GEAR HOUSING END

CABLE DRUMMOTOR END

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. Place taped end of cable into hole in cable drum as shown below. Use the 3/8-16NC x 1/2” long hex socket drive setscrew (included with drum assembly item #1) to secure cable to drum.

3. Carefully run winch in the "reel-in" direction. Keeping tension on end of cable, 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.

INSERT CABLE AS SHOWN FOR "A" ROTATION

OVERWOUND APPLICATION.

(UNDERWOUND APPLICATION REQUIRES CABLE TO

COME UNDER DRUM FROM OPPOSITE DI RE CTION

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 DI RE CTION

AND INSERTED IN THIS SAME CABLE POCKET.)

"B" ROTATION

DIRECTION

"A" ROTATION

DIRECTION

SETSCREW

PLUG

POSITION

CARTRIDGE POSITION

CARTRIDGE

POSITION

CABLE DRUM

ROTATION DIRECTION

CABLE DRUM

ROTATION DIRECTION

"B" ROTATION

"A" ROTATION

(REEL IN) RAISE INLET

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

2100 PSI RELIEF VALVE SETTING

15 GPM FLOW RATE

DO NOT EXCEED 20 GPM--MOTOR AND WINCH MAY BE DAMAGED

10 MICRON NOMINAL FILTRATION

TYPICAL LAYOUT

WITH BRAKE RELEASE SHUTTLE

MOTOR

BRAKE

PORT

SYSTEM

RELIEF

3 POSITION

4 WAY VALVE

(MOTOR SPOOL)

MAX. FLOW & PRESSURE AT RATED LOAD: 15 GPM 2500 PSI

HIGH PRESSURE LINE (.50 I.D. MINIMUM)

LOW PRESSURE LINE (.75 I.D. MINIMUM)

PUMP

PORT CONTROL

(DUAL CART. VALVE OPTION)

WORKING PRESSURE (PSI) AT 15 GPM

FLOW (GPM)

LINE PULL-FIRST LAYER (LB)

LINE SPEED-FIRST LAYER (FPM)

0 5 10 15

1000

2000

3000

4000

5000

6000

7000

8000

1000 2000 2500

BASED ON 24.9 CU. IN. MOTOR

1500500

PERFORMANCE CHARTS

9000

10000

NOTE: Dual counterbalance valve version at Maximum Flow will require an increased working pressure of 150 PSI.

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 operate. 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 dangerous 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 14):

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 release 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. If manual shift indicator light is present, the green light is lit when clutch is fully “ENGAGED”. DO NOT attempt to pull a load unless the green light is lit. To install light to the vehicle electrical system refer to the Electrical Schematic on page 15.

AIR CYLINDER CLUTCH SHIFTER (Refer to the dimensional drawing page 15): TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the cable. Apply air pres-

sure 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 engagement indicator light (green light) is lit. To install light to the vehicle electrical system refer to the Electrical Schematic on page 15.

MAINTENANCE

1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with broken strands, replace immediately. Cable and hook assembly (100’ long cable) P/N 524118 (“Y” drum) or (150’ long cable) P/N 524119 (STD drum) may be purchased from a Ramsey distributor.

2. Check that the clutch is fully engaging. See OPERATION instructions, above, for the appropriate 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 3 if it does.

4. Replace drum bushings and seals if seals begin to seep grease. Refer to the Overhaul Instructions, pages 7-12. Add additional lubricant, Mobilith SHC 007, to gears and drum bearings if required.

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. Refer to Winch Mounting, page 2.

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. Refer to Winch Mounting, page 2.

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 4.

WINCH RUNS TOO SLOW Low hydraulic system flow rate Check flow rate. Refer to Systerm Requirements and

Typical Layout page 4.

Motor worn out Replace motor

DRUM WILL NOT FREESPOOL

Clutch not disengaged. Check Adjustment of Manual Shifter, page 10.

Check Operation, page 5.

Winch not mounted squarely, causing end bearing to bind up

Check mounting. Refer to Winch Mounting, page 2.

Side mounted bolts too long, causing binding of ring gear (Item #15, page 16).

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 4.

CABLE BIRDNESTS WHEN CLUTCH IS DISENGAGED

Drag screw improperly adjusted Adjust nylon drag screw. Refer to Cable Installation,

page 3.

EXCESSIVE NOISE Hydraulic system flow too high Check flow rate. Refer to Typical Layout page 4.

Drum in bind, winch not mounted squarely Check mounting. Refer to Winch Mounting, page 2.

DRUM CHATTERS IN “REEL IN” DIRECTION

Low hydraulic system flow rate Check flow rate. Refer to Typical Layout page 4.

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. 8.

+ 16 hidden pages