Ramsey HDP35000 User Manual

OPERATING, SERVICE AND

MAINTENANCE MANUAL

MODEL HD-P35,000

INDUSTRIAL PLANETARY WINCH

WITH AIR TENSIONER AND 2 SPEED MOTOR

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND

OPERATION OF WINCH. SEE WARNINGS!

TABLE OF CONTENTS

INTRODUCTION .............................................................................................................. 1

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

SPECIFICA TIONS .......................................................................................................... 1a

WARNINGS .................................................................................................................... 1a

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

PERFORMANCE CHARTS .............................................................................................. 2

WINCH OPERATION ........................................................................................................ 3

CLUTCH OPERATION ..................................................................................................... 3

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

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

TROUBLE SHOOTING GUIDE ........................................................................................4

INSTRUCTIONS FOR OVERHAUL ..............................................................................5-11

MOUNTING CONFIGURATIONS .............................................................................. 12-13

DIMENSIONAL DRAWING ........................................................................................ 14-16

PARTS LIST AND PART DRAWING ..........................................................................18-21

LIMITED WARRANTY .......................................................................................Back cover

RAMSEY HYDRAULIC PLANETARY WINCH MODEL HD-P35,000

PLEASE READ THIS MANUAL CAREFULLY

This manual contains useful ideas in obtaining the most effi cient 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 specifi cations. 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 fi ll out the enclosed warranty card
and send it to Ramsey Winch Company . If you have any problems with our winch, please follow
instructions for prompt service on all warranty claims. Refer to back page for limited warranty .

SPECIFICATIONS* (LOW SPEED MODE) STANDARD DRUM

Rated Line Pull (lbs.)...................................................................................35,000

(Kgs.)......................................................................................15,909

Gear Reduction..........................................................................................33.16:1

Weight (without cable)...............................................................504 lb. (226 Kgs.)

*Rated line pull
per layer

*Cable capacity

*Line speed
(at 25 GPM)

Lbs.
Kg.

Ft.
M.

FPM
MPM

12LAYER OF CABLE

35,000
15,870

25
7

23.2

7.02

28,600
12,970

65
19

28.4

8.65

345

24,200
10,970

105

32

33.6

10.24

21,000

9,520

155

47

38.7

11.79

18,500

8,390

210

64

43.9

13.38

* These specifications are based on recommended wire rope .75" dia. EIPS and

11.9 cu.in./Rev. motor.

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

1

Continued

SPECIFICATIONS* SHORT DRUM

Rated Line Pull (lbs.)...................................................................................................35,000

(Kgs.)......................................................................................................15,909

Gear Reduction..........................................................................................................33.16:1

Weight (without cable)...............................................................................504 lb. (229 Kgs.)

*Rated line pull
per layer

*Cable capacity

*Line speed (low)
(at 25 GPM)

*Line speed (high)
(at 25 GPM)

Lbs.
Kg.

Ft.
M.

FPM
MPM

FPM
MPM

12LAYER OF CABLE

35,000
15,870

20

6.09
23

7.01
46

14.02

28,600
12,970

45

13.72
27

8.23
56

16.46

345

24,200
10,970

75

22.86
32

9.73
64

19.46

21,000

9,520

110

33.53
36

10.67
72

21.34

18,500

8,390

155

47.24
41

12.50
82

25

6

16,500

7,484

200

60.96
46

14.02
92

28.04

* These specifications are based on recommended wire rope .75" dia. EIPS and 11.9 cu.in./
Rev. motor at 2725 psi working pressure.

* Directional control valve required: 3-position, 4 way motor spool.
* Winch meets SAE J706.

WARNINGS:

CLUTCH MUST BE TOTALLY 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.

1a

HYDRAULIC SYSTEM REQUIREMENTS

)

Refer to the performance charts to properly match your hydraulic system to HDP-35000 winch performance.
The charts consist of:

(1) Line pull (lb.) fi rst layer vs. working pressure (PSI) and (2) Line speed (FPM) fi rst layer vs. fl ow (GPM).

Performance is based on a motor displacement of 1 1.9 cubic inches with 25 GPM maximum fl ow rate. See
page 10 for motor port size.

TYPICAL LAYOUT

PORT CONTROL

WITH BRAKE RELEASE SHUTTLE

MOTOR

BRAKE

PORT

A

B

PERFORMANCE CHARTS

(BASED ON 11.9 CU. IN./REV MOTOR)

PERFORMANCE WITH 11.9/5.95 IN 2-SPEED HYDRAULIC MOTOR:

LOW SPEED
HIGH SPEED

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

3 POSITION

4 WAY VALVE

(MOTOR SPOOL)

3

50

40

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

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

SYSTEM

RELIEF

FIRST LAYER

LINE PULL (Lbs.)

35000

30000

25000

20000

15000

10000

5000

0

500 1000 1500 2000 2500

PRESSURE (PSI)

35

30

25

20

15

FIRST LAYER

10

LINE SPEED (Ft/Min.)

5

3000

0

0 5 10 15 20

25

FLOW (GPM

2

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 confi dence in operating your winch and its use will become second na-
ture 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.

CLUTCH OPERATION

To engage clutch:

1. Move the clutch control valve to the “clutch engaged” position.

2. Anytime the temperature is below freezing, run the motor in the “cable out” direction only
until the drum starts to turn. In extreme cold temperatures (below 0˚ F/-18˚ C), pull out
on the cable by hand only until the drum starts to turn.

3. Wait at least 3 seconds for the clutch to fully engage, after which the winch is ready to
winch in the cable.

WARNING: Do not attempt to engage the clutch by fi rst running the winch

motor and then moving the clutch control valve to the “clutch-engaged” posi­tion while the motor is running. Do not start picking up the load at the same
time the clutch is being engaged.

To disengage clutch:

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

2. Move the clutch control valve to the “clutch-disengaged” position.

3. The cable may now be pulled off by hand.

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. Insert the end of cable, opposite hook end, into the hole in drum barrel. Secure cable to
drum barrel, using setscrew furnished with winch. TIGHTEN SETSCREW SECURELY.

3. Carefully run the 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.

3

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 in the gear housing cover. Be sure that it is not plugged.

3. Lubricate cable with light oil.

B. MONTHLY

1. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are
loose. Use grade 5 or better bolts.

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

C. ANNUALL Y

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

2. Fill the winch to the oil level plug with clean kerosene. Run the winch a few seconds with no load in
the reel in direction. Drain the kerosene from the winch.

3. Refi ll the winch to the oil level plug with all-purpose SAE 75W-90 synthetic gear oil.

4. Inspect frame and surrounding structure for cracks or deformation.

TROUBLESHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION

1. Seals damaged or

1. Replace seal.

worn.

OIL LEAKS FROM

2. Too much oil. 2. Drain excess oil. Refer to OPERATION.

WINCH

3. Damaged gaskets. 3. Replace gaskets.

1. Low fl ow rate 1. Check fl ow rate. Refer to HYDRAULIC SYS-

WINCH RUNS
TOO SLOW

2. Hydraulic motor

TEMS performance chart page 2.

2. Replace motor.

worn out.

CABLE DRUM
WILL NOT FREE­SPOOL

1. Too much air pres­sure to tensioner.

2. Clutch will not dis­engaged

1. Adj. air pressure lower & confi rm tensioner
still holds tension.

2. Check air pressure to clutch cylinder: 100 PSI
Minimum required. Refer to page 10 for port
location.

BRAKE WLL NOT
RELEASE

1. Brake line discon­nected or blocked.

1. Check brake function.

4

INSTRUCTIONS FOR OVERHAUL

DIS-ASSEMBLY

1. Drain oil from gear housing by removing oil drain plug, pipe plug #19 and relief fi t-
ting #25. Remove tensioner assembly.

19

25

OIL DRAIN PLUG

5