Ramsey RPH-12000 User Manual

OPERATING, SERVICE AND

MAINTENANCE MANUAL

MODEL RPH 12,000

PLANETARY WINCH

CAUTION

AND OPERATION OF WINCH. SEE WARNINGS!

: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION

TABLE OF CONTENTS

INTRODUCTIONS .......................................................................................................................1

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

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

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

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

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

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

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

OPERATIONS.............................................................................................................................. 5

MANUAL CLUTCH SHIFTER ......................................................................................................5

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

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

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

DIMENSIONAL DRAWINGS

RPH 12,000 WITH MANUAL CLUTCH SHIFTER ..................................................13

RPH 12,000 WITH AIR CYLINDER CLUTCH SHIFTER ........................................ 14

PARTS LIST AND PARTS DRAWINGS

RPH 12,000 WITH MANUAL CLUTCH SHIFTER ..................................................16-17

RPH 12,000 WITH AIR CYLINDER CLUTCH SHIFTER ........................................18-19

RPH 12,000 WITH BLOCKED CLUTCH................................................................. 20-21

LIMITED WARRANTY..................................................................................................................22

RAMSEY HYDRAULIC PLANETARY WINCH MODEL RPH 12,000

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:

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 TIE DOWN.

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.

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 at least one tie plate must be attached to the mounting feet at the bottom of the winch to maintain alignment. NOTE: least one tie plate must remain mounted at mid point of winch to maintain alignment. It is always desirable to use both tie plates in the final installed configuration.

If the winch is foot mounted, at

Angle Mounting Kit, #251006, 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 on page 14 must 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 Lg. Gr. 5 capscrews with lockwashers will be needed to mount winch. Capscrews should be torqued to 85 ft. lb. (115 Nm.).

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 maximum of .56 inch thread length engagement in the tapped holes in sides of each end bearing. Refer to page 13. Use of excessive length bolts will not allow tie plate to tighten down properly. Torque bolts to 55 ft. lbs. (75 Nm).

CABLE INSTALLATION

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 3/8-16NC x 1/2 lg. Hx.

Soc. drive setscrew (part of 234171 drum assembly) 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 #21) and turn nylon screw (item #19) 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.

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts below to properly match your hydraulic system to the winch performance. The charts consist of: (1) first layer line pull (LB) vs. working pressure (PSI), (2) first layer line speed (FPM) vs. flow (GPM), and (3) relief valve setting (PSI) vs. flow (GPM). A motor spool directional control valve is required.

SYSTEM REQUIREMENTS:

2500 PSI RELIEF VALVE SETTING*

15 GPM FLOW RATE**

10 MICRON NOMINAL FILTRATION

*CAUTION: DO NOT EXCEED 20 G.P.M. IF EXCEEDED, MOTOR AND WINCH MAY BE DAMAGED

TYPICAL LAYOUT

PERFORMANCE CHARTS

PERFORMANCE WITH 24.0 CU. IN. HYDRAULIC MOTOR

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 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.

When pulling a heavy load place a blanket, jacket or 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 page 13) TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the cable.

Pull handle out and rotate 90o. With handle in the "DISENGAGED" position, cable may now be freespooled from drum.

TO ENGAGE CLUTCH: Pull handle out, rotate 90o 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.

AIR CYLINDER CLUTCH SHIFTER (Refer to page 14) TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the cable. Apply air pressure 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. DO NOT attempt to pull a load unless the green light is lit. To connect light to the vehicle electrical system refer to the Electrical Schematic on page 14.

MAINTENANCE

1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with broken strands, replace immediately.

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 shaft and work clutch IN and OUT several times to lubricate inside of clutch cylinder.

3. Check to see that drum cable does not overrun (birdnest) when freespooling. Refer to page 3.

4. Replace drum bushings and seals when seals begin to seep grease. Refer to OVERHAUL

INSTRUCTIONS, page 7. Add additional lubricant, Mobilith SHC 007, to gears if required.

TROUBLE SHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION / ACTION

DRUM WILL NOT ROTATE Brake damaged. Inspect and replace brake. AT NO LOAD Gears damaged. Inspect and replace damaged gears.

Brake not releasing See section below.

DRUM WILL NOT ROTATE Load greater than rated Refer to Specifications pg.1 UNDER LOAD capacity of winch. for line pull rating.

Low hydraulic system Check pressure. Refer to HYDRAULIC pressure. SYSTEMS performance charts pg. 4.

WINCH RUNS TOO SLOW Low hydraulic system flow rate. Check flow rate. Refer to HYDRAULIC SYSTEMS flow chart page 4.

Motor worn out. Replace motor.

DRUM WILL NOT Clutch not disengaged. Check clutch shifter. Refer to page 5. FREESPOOL Check ADJUSTMENT. Refer to page 10.

BRAKE WILL NOT RELEASE Brake damaged. Inspect and replace. Refer to page 8 & 11 for overhaul.

CABLE BIRDNESTS WHEN Drag screw improperly Adjust nylon drag screw. CLUTCH IS DISENGAGED adjusted. Refer to pg. 3.

EXCESSIVE NOISE Hydraulic system flow too high Check flow rate. Refer to HYDRAULIC SYSTEMS flow chart pg. 4.

DRUM CHATTERS, Low hydraulic system flow. Check flow rate. Refer to HYDRAULIC in "REEL IN" direction SYSTEMS flow chart pg. 4.

Low hydraulic system Check relief valve setting. Refer to relief pressure setting. HYDRAULIC SYSTEMS pg. 4.

OIL SEEPAGE FROM Brake piston not sealing properly. Replace o-ring and back up rings on brake BREATHER VENT OF piston. Refer to page 8 & 11. BRAKE HOUSING

GREASE SEEPAGE FROM Grease applied to seals during NONE. Normal condition during the first JOINTS IN MOTOR assembly by the motor manufacturer. few times the winch is operated.

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