Ramsey RPH-30000T-117 User Manual

OPERATING, SERVICE AND MAINTENANCE MANUAL

MODEL RPH-30000T-117

INDUSTRIAL PLANETARY WINCH

Intended Purpose:

CAU

TION:

AND OPERATION OF WINCH. SEE WARNINGS!

READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION

Vehicle Recovery and Pulling of Loads

TABLE OF CONTENTS

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

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

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

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

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

CABLE INSTALLATION/TENSIONER OPERATION..........................................................2

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

PERFORMANCE CHARTS................................................................................................. 3

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

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

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

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

INSTRUCTIONS FOR OVERHAUL...............................................................................5-14

MOUNTING CONFIGURATIONS..................................................................................... 14

DIMENSIONAL DRAWING............................................................................................... 15

PARTS LIST AND PART DRAWING............................................................................16-17

LIMITED WARRANTY..........................................................................................back cover

RAMSEY HYDRAULIC PLANETARY WINCH MODEL RPH 30000T-117

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 our 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.

NOISE LEVEL 76 dB(A)

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.

WINCH FRAME MOUNTING

BRAKE

PORT

MOTOR

HYDRAULIC SYSTEM SCHEMATIC

SYSTEM

RELIEF

MAX. FLOW & PRESSURE AT RATED LOAD: 15 GPM 2800 PSI

PUMP

3 POSITION

4 WAY VALVE

(MOTOR SPOOL)

DUAL - A & B PORT

MOTOR CONTROL VALVE

WITH BRAKE RELEASE SHUTTLE

SYSTEM REQUIREMENTS:

*CAUTION: DO NOT EXCEED 20 GPM, IF EXCEEDED, MOTOR AND WINCH MAY BE DAMAGED

INSTALLER MUST DETERMINE TYPE OF

OPTIONAL EXTERNAL CASE DRAIN LINE

Use (8) 5/8 inch diameter grade 5 or better bolts to attach mounting frame to wrecker.

CABLE INSTALLATION / TENSIONER OPERATION

CAUTION: The cable tensioner is not intended to be energized on a bare drum. Before applying air to the cable tensioner, engage the clutch

and run the winch in the reel in direction winding one full wrap of cable on the drum. This prevents damage to the cable tensioner.

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. Engage the clutch and carefully run the winch in the "reel-in" direction. Keeping tension on end of cable, spool about five wraps of cable onto the drum and stop. Using a hammer, tap these five wraps tightly over against the cable anchor flange side of the cable drum. Finish winding all the cable onto the cable drum. As cable winds onto the drum, watch the tensioner. Tensioner must be free to move without obstruction to function properly. If tensioner touches any surrounding structure, correct the problem.

Adjust the Free-spool Effort of the Cable Tensioner

Disengage the winch clutch and free spool some cable off the drum. Adjust the air pressure to the cable tensioner to achieve the desired free spool effort that also prevents "bird nesting" of the cable.

CAUTION: DO NOT EXCEED 80 PSI AIR PRESSURE TO THE AIR TENSIONER ACTUATORS.

Once you have adjusted the air pressure to the desired level, only minor adjustment may be required if your pressure regulator setting drifts.

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts, on page 3, to properly match your hydraulic system to RPH 30000T-117 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 2 speed motor displacement of 9.6/4.8 cubic inches with 15 GPM maximum flow rate. See page 14 for motor port size.

CAUTION: SYSTEM BACK PRESSURE MUST NOT EXCEED 50 PSI OR BRAKE SHAFT SEAL FAILURE CAN OCCUR. IF BACK PRESSURE EXCEEDS 50 PSI, AND CANNOT BE REDUCED, AN EXTERNAL CASE DRAIN LINE SHOULD BE RUN FROM THE MOTOR CASE DRAIN PORT (SEE PAGE 15) TO TANK OR A LINE/CONNECTION THAT HAS A PRESSURE BELOW 50 PSI. THE DRAIN LINE MUST BE ROUTED SO THAT SOMEWHERE ALONG ITS PATH, THE LINE IS HIGHER THAN THE MOTOR SHAFT CENTERLINE.

PERFORMANCE CHARTS

CLUTCH OPERATION

1. Move the clutch control valve to the "clutch-engaged" position.

2. Anytime the temperature is below freezing, run motor in the "cable out" direction only until the drum starts to turn.

2a. In extreme cold temperatures (below 0o F/-18o 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 first 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.

Move the clutch control valve to the "clutch-disengaged" position.

The cable may now be pulled off by hand.

2 SPEED OPERATIONS

Application of 12V or 24V DC, depending on your model, to the 2 speed selector valve will shift the motor to high speed/low torque mode.

WARNING: DO NOT CHANGE SPEED SELECTOR WHEN WINCH IS IN OPERATION. DAMAGE TO THE DRIVE TRAIN AND/OR MOTOR MAY RESULT.

WINCH 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. 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 in top of the gear housing. 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. ANNUALLY

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. Refill the winch to the oil level plug with all purpose SAE 80W-140 gear oil.

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

TROUBLE SHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION

OIL LEAKS FROM WINCH 1. Seals damaged or worn. 1. Replace seal.

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

3. Damaged gasket. 3. Replace gasket.

4. Replace brake, check back pressure to

4. Damaged brake shaft seal.

WINCH RUNS TOO SLOW 1. Low flow rate.

2. Hydraulic motor worn out. 2. Replace motor.

CABLE DRUM WILL NOT FREESPOOL 1. Clutch not disengaged.

BRAKE WILL NOT RELEASE 1. Air in hydraulic system. 1. Bleed air from brake. Refer to page 13.

motor. If back pressure is more than 50 PSI, reduce back pressure or add external case drain line.

1. Check flow rate.Refer to flow HYDRAULIC SYSTEMS flow chart page

1. Check air pressure to clutch cylinder 90 PSI minimum required-Refer to page 14.

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