Ramsey RPH-50000 User Manual

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Page 1

OPERATING, SERVICE

AND MAINTENANCE

MANUAL

MODEL RPH-50,000 INDUSTRIAL

PLANETARY WINCH

CAUTION

AND OPERATION OF WINCH. SEE WARNINGS!

: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION

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Page 3

TABLE OF CONTENTS

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

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

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

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

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

CABLE INSTALLATION........................................................................................... 2

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

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

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

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

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

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

INSTRUCTIONS FOR OVERHAUL.........................................................................5-12

MOUNTING CONFIGURATIONS............................................................................13

DIMENSIONAL DRAWING......................................................................................14

PARTS LIST AND PART DRAWING.......................................................................15-16

LIMITED WARRANTY.............................................................................................Back Cover

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RAMSEY HYDRAULIC PLANETARY WINCH MODEL RPH 50,000

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*

Rated Line Pull (lbs.).........................................................................50,000

(Kgs.)..............................................................................22,670

Gear Reduction................................................................................51.35:1

Weight (without cable)....................................................689 lb. (313 Kgs.)

12LAYER OF CABLE

*Rated line pull per layer

*Cable capacity

*Line speed (at 25 GPM)

dia. extra improved plow steel or equivalent

Lbs. Kg.

Ft. M.

FPM MPM

50,000 22,670

30 9

7.0

40,900 18,550

65 19

8.6

34,600 15,690

110

10.1

30,000 13,600

160

11.7

5**

26,400 11,970

220

13.2

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

WARNINGS:

VERIFY PROPER COUNTERBALANCE VALVE CARTRIDGE AND PLUG POSITION FOR SPECIFIC INSTALLATION.

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.

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WINCH MOUNTING

Use (8) 3/4" diameter grade 5 or better bolts to attach winch to the wrecker. Before operating the winch for the first time, remove the cover from the breather vent at the back of the air

cylinder and the relief fitting on top of the clutch housing.

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.

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts to properly match your hydraulic system to RPH-50000 winch performance. The charts consist of:

(1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) Line speed (FPM), first layer vs. flow (GPM).

Performance based on a motor displacement of 9.6 cubic inches with 25 GPM maximum flow rate. See page 14 for motor port size.

TYPICAL LAYOUT

DUAL-A & B PORT CONTROL

WITH BRAKE RELEASE SHUTTLE

MOTOR

BRAKE

PORT

PUMP

ALTERNATE CARTRIDGE

LOCATION

(AS DESCRIBED

IN VIEW A-A

ON PAGE 13)

3 POSITION

4 WAY VALVE

(MOTOR SPOOL)

SYSTEM

RELIEF

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PERFORMANCE CHARTS

(BASED ON 9.6 CU. IN./REV MOTOR)

50,000 45,000 40,000 35,000

30,000 25,000 20,000 15,000

LINE PULL (LB.), FIRST LAYER

10,000

0 1,000 2,000 3,000

WORKING PRESSURE (PSI)

LINE SPEED (FPM), FIRST LAYER

0 5 10 15 20 25

FLOW RATE (GPM)

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 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.

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

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

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.

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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.

Lubricate cable with light oil.

B. MONTHLY

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 tie bars and surrounding structure for cracks or deformation.

TROUBLE SHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION

1. Seals damaged or worn. 1. Replace seal.

OIL LEAKS FROM

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

WINCH

3. Damaged gaskets. 3. Replace gaskets.

1. Low flow rate. 1. Check flow rate. Refer to

WINCH RUNS TOO SLOW

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

1. Clutch not disengaged. 1. Check air pressure to clutch CABLE DRUM WILL NOT FREESPOOL

OPERATION.

HYDRAULIC SYSTEMS performance chart page 2.

cylinder 100 PSI min. required Refer to page 14 for port location.

BRAKE WLL NOT RELEASE

LOAD LOWERS TOO FAST

1. Brake line disconnected or

blocked.

1. Hydraulic lines to counter-balance

valve incorrectly installed and/or cartridge plug position incorrect for drum rotation direction to reel cable in.

1. Check brake function. Refer to page 12.

1. Refer to View A-A pg. 14 for correct installation.

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INSTRUCTIONS FOR OVERHAUL

DIS-ASSEMBLY

1. Drain oil from gear housing #10 by removing pipe cap #43 from pipe nipple in end bearing. Remove reducer #42 and relief fitting #38. If new air cylinder is required, remove air cylinder #33 from cover by removing (4) capscrews #23.

Remove washer #25, nut #26, setscrew #21, and insert #31 from end of air cylinder rod. Apply

Loc-tite to threads of nut #26 and thread onto setscrew #21 to 3/8” from drive end, as shown below. Apply Loc-tite to threads of setscrew and thread insert #31 over end of setscrew and against nut. Use setscrew and nut to thread insert #31 into end of air cylinder rod. Tighten nut against cylinder rod, keeping 3/8” distance from drive end of setscrew to nut. If breather vent #39 is damaged, remove and replace.

AIR CYLINDER ROD

APPLY LOC-TITE TO SETSCREW

3/8

2. Disconnect tube #46 from elbow #32 on valve #47 and fitting #33 on bottom of brake #35. Remove motor #40 and gasket #35b by removing (2) capscrews #20. Remove valve #47, if needed, from motor by loosening (3) capscrews #18, as shown on page 15.

35b

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3. Remove brake assembly screws #16 from brak e 35a to access (2) mounting screws #19 attaching

brake adapter plate #35d to end bearing #9. CAUTION: BRAKE IS SPRING-LOADED BY CLUTCH SPRING AND MUST

BE RESTRAINED AGAINST END BEARING AS MOUNTING SCREWS ARE REMOVED

. Remove coupling #7 and gasket #35e

from end bearing. Take note of mounting configuration for proper mounting of parts during reassembly.

35c

35e

35d

35a

35e

4. Remove winch from tie bars #2 and #3 by removing (8) capscrews #17, (8) lockwashers #24, and

(4) shoulder bolts #29. Pull motor end bearing #9 from drum assembly #1.

OUTER-MOST

CAPSCREW

INNER-MOST CAPSCREWS

OUTER-MOST

CAPSCREW

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5. Pull drum assembly #1 upward from end bearing #10. Remove quad-rings #41 from grooves in

drum bushings. Remove input shaft #11, clutch springs #44 & #45 and washers #27 & #28 from end bearing. Examine splined ends of input shaft for signs of wear, replace if damaged.

Examine drum assembly #1 for signs of wear. If splines inside of drum driver (332148) are damaged, drum driver must be replaced. Remove drum driver by unscrewing (8) capscrews (414978). If bushings show signs of wear, replace by pressing old bushings from drum and removing o-rings from grooves in drum and drum driver. Place well-oiled o-rings (462043) into grooves in drum and drum driver. Press new bushing (412078) into end of drum opposite drum driver and press bushing (412079) into drum driver until flange of bushings are flush against drum and driver.

O-RING 462043

DRUM DRIVER GROOVE

BUSHING 412079

O-RING

462043

BUSHING

412078

DRUM BUSHING

ASSEMBLY

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6. Remove output coupling #8 and coupling shaft #6 from end bearing #10. Examine bearings #13

pressed in output coupling for signs of wear. Replace bearings, if necessary, by pressing old bearings from coupling and press new bearings into each end of output coupling. Place coupling shaft into bearings.

7. Remove (12) capscrews #15 to pull gear-housing cover #4 and gasket #36 from ring gear #49.

Remove input thrust washer, sun gear and carrier assemblies from inside of ring gear. Remove ring gear #4 and gasket #36 from end bearing #10. Examine shifter shaft #12 for signs of wear, replace if necessary. Examine bushing #14 for signs of wear. Replace bushing, if necessary, by pressing old bushing from housing and pressing new bushing into place.

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RE-ASSEMBLY

8. NOTE: DETERMINE MOUNTING CONFIGURATION OF WINCH (R.H. or L.H. MOUNTED)

BEFORE ATTACHING TIE BARS TO WINCH, TO ASSURE PARTS ARE MOUNTED TO PROPER SIDE, REFER TO WINCH MOUNTING CONFIGURATIONS ON PAGE 13.

Seat well-oiled quad-ring #41 into groove of bushing in each end of drum assembly #1. Carefully

set drum assembly down over motor end bearing #9. Lift gear-housing end bearing #10 and set into place on drum assembly. Attach tie bars #2 and #3 using (8) capscrews #17 and lockwashers #24. Install (4) shoulder bolts #29 and hand tighten. Tighten (4) innermost capscrews securely, check rotation of cable drum. Tighten (4) outer-most capscrews securely, check rotation of cable drum. Torque capscrews, in innermost then outer-most pattern shown below, to 430 ft.-lbs. each. Torque shoulder bolts to 30 ft-lbs. each. Check rotation of cable drum assembly. It must rotate freely with no tight spots.

OUTER-MOST

CAPSCREW

INNER-MOST

CAPSCREWS

OUTER-MOST

CAPSCREW

9. Place end (with longest splines) of output coupling #8 through end bearing bushing #13 and mesh

coupling spline with spline inside of drum. Slide clutch spacer #30 over end and against shoulder of shifter shaft #12. Place shifter shaft through washer #27 and into shaft coupling #6, meshing splines of shifter shaft with splines in shaft coupling.

LONGEST SPLINES

Page 13

10. Set gasket #36 into place on gear housing end bearing #10. Place ring gear #49 onto end bearing,

aligning holes in ring gear with holes in gasket and gear housing end bearing. Use (2) capscrews to temporarily secure ring gear to end bearing. Place (2) gear carrier assemblies into ring gear meshing carrier gears with ring gear. Slide input sun gear over shifter shaft #12 and mesh with teeth of input carrier. Apply grease to input thrust washer and place into slots of gearbox cover #4. Place gasket #36 into position on gearbox cover with sealer. Remove (2) temporary capscrews and attach cover and gasket to ring gear end bearing. Use (12) capscrews #15 to secure gearbox to gear housing end bearing. Torque capscrews to 87 ft-lbs. each, in a criss-cross pattern.

11. Pull rod from air cylinder as far as possible. Slide washer #25 over setscrew #20 and against nut

attached to air cylinder rod. Place setscrew into hole of shifter shaft #12 and attach air cylinder to gear box cover using (4) capscrews #22. Apply Loc-tite PST thread sealer to threads of capscrews. Torque capscrews to 5 ft-lbs. each, in criss-cross pattern.

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12. Gently tap key #5 into keyway of input shaft #11. Liberally apply grease to shoulder of input shaft.

Place 1-3/4 OD washer #28 over end of shaft and against shoulder of shaft. Place spring #44 inside of spring #45 and place both springs over shaft and against washer #28. Slide 2-3/8 OD clutch washer #27 over splined end of shaft and against springs. Use grease to hold springs and washers in place on shaft. Place splined end of shaft through drum and into output coupling #7. Mesh spline of input shaft with internal spline of coupling shaft inside of drum.

Align keyway of coupling with key and end of input shaft below. Slide coupling over end of shaft

#11. Place gasket #35e into position on motor mounting surface of end bearing #9. Insert brake shaft with key #35c into coupling. Use (2) screws #19 to attach brake adapter plate #35d to motor end bearing. Torque capscrews to 85 ft.-lbs. each. Apply second gasket #35e to other side of adapter plate. Re-attach brake #35a to brake adapter plate using brake assembly screws #16. Torque capscrews to 97 ft.-lbs. each.

Note: Care must be taken to assure adapter plate and brake are seated properly prior to installing

1/2-13NC assembly bolts. Damage will occur to rotor stack or shaft snap ring if not properly installed.

35c

35e

35d

35a

35e

13. Attach motor #40 with well-oiled gasket #35b to brake #35. Use (2) capscrews #20 and torque to

74 ft.-lbs. each. Securely connect tube #46 to elbow #32, in bottom of valve #47, and fitting #33 in bottom of brake #35.

35b

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14. Apply Permatex to thread of plug #43. Thread plug into tapped hole in bottom of gear housing end bearing #10. Pour approximately 4.75 pints of SAE 80W-140 oil into end bearing. Check oil level by removing oil plug noted below. Insert relief fitting #38 and thread reducer #42 into end bearing at oil fill hole. Be sure breather vent #39 and relief fitting #38 are not damaged and in good operating condition. Replace if necessary.

OIL LEVEL PLUG

Install winch and connect pressure lines. Apply at least 230 PSI pressure to release brake and verify that brake releases, by observing that the winch drum rotates.

15. Check proper operation of clutch by applying air pressure to clutch air cylinder to disengage clutch. Verify that winch freespools. Re-engage clutch. A loud noise should be heard when the clutch engages. Winch drum should not freespool.

16. Operate winch forward and reverse to verify that drum rotates.

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CHANNEL SIDE

ANGLE SIDE

R. H. MOUNTING

CONFIGURATION

CHANNEL SIDE

ANGLE SIDE

L. H. MOUNTING

CONFIGURATION

WINCH MOUNTING CONFIGURATIONS

Page 17

42.95 (RPH-50)

1090,9

8.78

223,0

23.19 589,0

17.56 446,0

10.41 264,3

1/8-27NPT PORT

6.25

158,7

20.25 514,3

STATIC LOAD HOLDING BRAKE

90,4

3.56

78,5

3.09

9.40

238,8

(9.6 CU IN MOTOR)

2.50 63,5

WITH PLUG AND CARTRIDGE IN POSITION SHOWN CABLE DRUM ROTATES CLOCKWISE, AS VIEWED FROM MOTOR END OF WINCH, TO REEL CABLE IN. LOCATION OF PLUG AND CARTRIDGE MUST BE REVERSED FOR OPPOSITE ROTATION

.81

20,6

14.50 368,3

7.25

184,2

DRUM

FLANGE

20.62 523,7

DIA.

16.00 406,4

7.00 DIA.

177,8 DRUM

10.31 261,9

PRESSURE IN GIVES COUNTER-CLOCKWISE DRUM ROTATION VIEWED FROM MOTOR END

2.50 63,5

5.63

143,0

(TYP 4-PLACES)

.29 7,4

1/8-27NPT PRESSURE PORT (100 TO 120 PSI) FOR DISENGAGING CLUTCH. (CLUTCH IS SPRING ENGAGED.) SEE END VIEW FOR TRUE ORIENTATION OF PORT.

12.25 311,1

1.06 26,9

.81 (20,6 mm) DIA. THRU (TYP. 4 PLACES EACH SIDE)

PNEUMATIC

PORT LOCATION

2.69 68,3

12,7

.50

1.56 39,6

4.00

101,6

PRESSURE IN GIVES CLOCKWISE DRUM ROTATION VIEWED FROM MOTOR EN D

1.62 41,1

VIEW

MOTOR CONTROL VALVE DETAIL

A-A

1.062-12 SAE STRAIGHT THREAD

O-RING PORT (TYP. 2 PLACES)

MODEL RPH-50,000

R.H. MOUNTING CONFIGURATION

Page 18

35b

35c

35e

35a

LONGEST SPLINES

35d

35e

RPH 50,000 WINCH

Page 19

PARTS LIST – RPH 50000

ITEM QTY. PART # DESCRIPTION ITEM QTY. PART # DESCRIPTION

1 1 234156 DRUM ASSEMBLY 27 2 418460 WASHER – CLUTCH, 2-1/4 x .938 ID 2 1 243037 TIE BAR 28 1 418440 WASHER – SPRING, 1-3/4 OD 3 1 243038 TIE BAR 29 4 418453 SHOULDER BOLT 4 1 328158 GEAR BOX COVER 30 1 426044 SPACER – CLUTCH 5 1 342081 KEY – RD. END 31 1 426045 INSERT 6 1 324283 COUPLING – SHAFT 32 1 432018 7 1 299733 COUPLING – BRAKE 33 1 432023 FITTING – 7/16-20 STRAIGHT 8 1 324295 COUPLING – OUTPUT 34 1 433017 AIR CYLINDER 9 1 338340 END BEARING – MOTOR 35 1 438037 BRAKE ASSEMBLY: 10 1 338341 END BEARING – GEAR a 1 BRAKE 11 1 357492 SHAFT – INPUT b 1 MOTOR GASKET 12 1 358064 SHAFT – SHIFTER c 1 BRAKE SHAFT KEY 13 2 402117 BEARING d 1 ADAPTER PLATE 14 1 412086 BUSHING – THRUST e 2 ADAPTER PLATE GASKET 15 12 414557 CAPSCREW 1/2-13NC X 6 LG. HX HD GR 5 36 2 442210 GASKET – GEAR BOX 16 2 414595 CAPSCREW 1/2-13NC X 3 1/2 LG HX HD GR 8 37 1 442217 GASKET – AIR CYLINDER 17 8 414784 CAPSCREW 7/8-9NC X 2 LG. HX HD GR 5 38 1 456008 RELIEF FITTING 18 3 414935 CAPSCREW 3/8-16NC X 2-1/2 LG. HX SOC HD 39 1 456038 BREATHER VENT 19 2 414947 CAPSCREW 1/2-13 NC X 1LG. SOC HD 40 1 458076 MOTOR – HYDRAULIC (W/KEY INCLUDED) 20 2 414948 CAPSCREW 1/2-13 NC X 1-1/4 LG. SOC HD 41 2 462040 QUAD. RING 21 1 416051 SETSCREW 5/16-24NF X 1 LG. SOC HD 42 1 468004 REDUCER 22 1 416072 SETSCREW 1/2-13NC X 3/4 LG. HX SOC HD 43 1 468019 PIPE PLUG 23 4 416211 CAPSCREW #10-24 NC X 3.25 HX SOC HD 44 1 494106 SPRING 24 8 418261 LOCKWASHER 7/8 MED. SECT 45 1 494114 SPRING – CLUTCH, OUTER 25 1 418429 WASHER - THRUST 46 1 509124 TUBE ASSEMBLY 26 1 418430 NUT – 5/16-24 NF X 1/8 THK, LOCK 47 1 516014 VALVE – CONTROL 48 1 468040 PIPE PLUG 49 1 530172 GEAR BOX

FITTING – HYD. 7/16-20 90° ELBOW

Page 20

LIMITED WARRANTY

RAMSEY WINCH warrants each new RAMSEY WINCH to be free from defects in material and workmanship for a period of one (1) year from date of purchase.

The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at the Manufacturer's factory, or at a point designated by the Manufacturer, of such part that shall appear to the Manufacturer, upon inspection of such part, to have been defective in material or workmanship.

This warranty does not obligate RAMSEY WINCH to bear the cost of labor or transportation charges in connection with the replacement or repair of defective parts, nor shall it apply to a product upon which repair or alterations have been made, unless authorized by Manufacturer, or for equipment misused, neglected or which has not been installed correctly.

RAMSEY WINCH shall in no event be liable for special or consequential damages. RAMSEY WINCH makes no warranty in respect to accessories such as being subject to the warranties of their respective manufacturers.

RAMSEY WINCH, whose policy is one of continuous improvement, reserves the right to improve its products through changes in design or materials as it may deem desirable without being obligated to incorporate such changes in products of prior manufacture.

If field service at the request of the Buyer is rendered and the fault is found not to be with RAMSEY WINCH's product, the Buyer shall pay the time and expense to the field representative. Bills for service, labor or other expenses that have been incurred by the Buyer without approval or authorization by RAMSEY WINCH will not be accepted.

See warranty card for details.

RAMSEY WINCH COMPANY

Post Office Box 581510 Tulsa, Oklahoma 74158-1510 Telephone: (918) 438-2760 FAX: (918) 438-6688 OM-914103-0509-J