Ramsey RPH-8000 User Manual [en, de, es, fr]

OPERATING, SERVICE AND MAINTENANCE MANUAL

English . . . . . . . . . . . . . . . . . . . . .1

Français . . . . . . . . . . . . . . . . . . .22

Deutsch . . . . . . . . . . . . . . . . . . .43

Español . . . . . . . . . . . . . . . . . . .64

MODEL RPH-8000 PLANETARY WINCH

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!

Ramsey Winch Company

P.O. Box 581510 - Tulsa, OK 74158-1510 USA

Phone: [phone] - Fax [phone]

Visit us at http://www.ramsey.com

OM-914195-0309-C

TABLE OF CONTENTS

INTRODUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 ADJUSTING THE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 HYDRAULIC SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 TYPICAL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 OVERHAUL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11 DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 PARTS LIST AND PARTS DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-21

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.

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*	Rated Line Pull	(lbs.)	…………………………………………………				8,000
		(Kg.)	…………………………………………………				3,620
	Gear Reduction	……………………………………………………………					5.1:1
	Weight (without cable)		RPH-8000 STD. ……..…....………. 90 lbs. (40.9 Kg)
			RPH-8000 "Y" ………….………….. 85 lbs. (38.6 Kg)
	LAYER OF CABLE		1	2	3	4	5
	*Rated line pull	lbs.	8,000	6,800	5,900	5,200	4,700
	per layer	Kg.	3,620	3,080	2,670	2,350	2,120
	* Cable Capacity per Layer
	RPH-8000 (STD.	ft.	25	55	90	130	170
	DRUM)	m	7	16	27	39	51
	RPH-8000 ("Y"	ft.	15	35	60	85	115
	DRUM)	m	4	10	18	25	34
	* Line Speed (at	FPM	50	58	67	76	84
	15 GPM)	MPM	15.2	17.6	20.3	23.1	25.5
	* These specifications are based on recommended wire rope of 3/8" (10mm)
	galvanized aircraft cable, or EIPS cable and a 14.9 cu.in./Rev. motor.

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

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 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.

3

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 85 ft-lb (115 Nm) torque.

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 .50 inch thread length engagement in the tapped holes in side of each end bearing. Use of excessive length bolts will damage the winch and prevent freespool of the drum. Torque bolts to 55 ft-lbs. (75 Nm).

MOTOR END

CABLE DRUM

GEAR HOUSING END

FOOT MOUNT

TIEPLATE AT SIDE LOCATION

TIEPLATE AT FOOT (BASE) LOCATION

MID MOUNT

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.

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 direction, exchange positions of the cartridge and plug shown at right.

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.

"B" ROTATION DIRECTION

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.

4

CABLE DRUM	CABLE DRUM
ROTATION	ROTATION

(REEL IN)

RAISE INLET

"A" ROTATION

"B" ROTATION

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 brake for drift, refer to page 6.

4.Check to see that the drum cable does not overrun (“birdnest”) when freespooling. Refer to page 4 if it does.

5.Replace drum bushings and seals if seals begin to seep grease. Refer to the Overhaul Instructions, pages 9-11. Add additional lubricant, Mobilith SHC 007, to gears and drum bearings if required.

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 12):

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 13.

AIR CYLINDER CLUTCH SHIFTER (Refer to the dimensional drawing page 13):

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. To install light to the vehicle electrical system refer to the Electrical Schematic on page 13.

5

ADJUSTING THE BRAKE

All parts of the oil-cooled automatic safety brake are bathed in oil. When the brake wears to the point that the load begins to drift, the brake can be adjusted as follows:

1.Loosen the lock nut on the adjusting screw (see drawing on Page 10).

2.Increase the brake torque by turning the adjusting screw clockwise. CAUTION: Only 1/4 turn is usually required to adjust the brake. Over-tightening can cause overheating, and damage to the brake parts. Tighten the lock nut after adjustment is completed.

If the brake does not respond to adjustment, then a new flat spring (item #3) and/or brake discs (item #31) may be needed.

Brake torque can be checked/set as follows: A torque wrench can be equipped with a special adapter to fit the input coupling of the winch. The adapter can be made by welding a 1" diameter straight motor shaft, with 1/4" key, in a 1" hex socket as shown in the following figure.

TORQUE WRENCH

1" DIA. STRAIGHT SHAFT WITH 1/4 " WOODRUFF KEY

1" HEX. SOCKET WELDED TO SHAFT

MOTOR SHAFT COUPLING

This special adapter will fit into the motor shaft coupling. Place coupling onto drum shaft in winch. Turn the torque wrench so that the drum turns in the "CABLE OUT" direction (lowering direction). The torque setting for the brake should be 155 to 160 ftlbs. If the torque wrench does not show the proper torque value, the adjusting screw should be adjusted 1/4 turn (clockwise if torque is low or counter-clockwise if torque is high). Each time the adjusting bolt is turned, check the torque reading. Continue this procedure until the proper torque reading is achieved. Then tighten the lock nut. If proper adjustment cannot be made, follow overhaul instructions on Page 10.

After the brake has been adjusted to the proper torque setting, as described above, disengage clutch. Start vehicle engine and run winch in the "CABLE IN" (raise direction). Allow winch to run in this direction for one minute.

Place your hand on the brake housing. If housing is not hot to the touch then run winch in the reverse direction (cable out) for one minute. Brake housing should begin to heat.

When these conditions exist, proper installation has been made.

6

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
	2500 PSI RELIEF VALVE SETTING
		15 GPM FLOW RATE
	DO NOT EXCEED 20 GPM--MOTOR AND WINCH MAY BE DAMAGED
	10 MICRON NOMINAL FILTRATION
	1000 PSI MAXIMUM BACK PRESSURE
TYPICAL LAYOUT		HIGH PRESSURE LINES
		(.5 I.D.)
	CONTROL VALVE
	3 POSITION 4 WAY
	CYLINDER SPOOL
PUMP INLET LINE
(1.00 I.D.)	PUMP
	RELIEF VALVE
	FLUID FILTER
	FLUID	HYDRAULIC
		WINCH MOTOR
	RESERVOIR
	LOW PRESSURE LINES	LOW PRESSURE LINES

		(.75 I.D.)	(.75 I.D.)
PERFORMANCE CHARTS
50

LINE SPEED-FIRST LAYER (FPM)

40					8000
				(LB)	7000
					6000
30				LAYER	5000
				FIRST-PULL	4000
					3000
20
				LINE	2000
					1000
10					0
					0	500	1000	1500	2000	2500
0	5	10	15
FLOW (GPM)					WORKING PRESSURE (PSI) AT 15 GPM

BASED ON 15.5 CU. IN. MOTOR

7

TROUBLESHOOTING GUIDE

CONDITIONS	POSSIBLE CAUSE	CORRECTION/ACTION
DRUM WILL NOT ROTATE	Winch not mounted squarely, causing end bearing	Check mounting. Refer to Winch Mounting, page 4.
AT NO LOAD	to bind up
	Brake damaged	Inspect and replace brake
	Gears damaged	Inspect and replace damaged gears
DRUM WILL NOT ROTATE	Winch not mounted squarely, causing end bearing	Check mounting. Refer to Winch Mounting, page 4.
UNDER LOAD	to bind up
	Load greater than rated capacity of winch	Refer to Specifications page 3 for line pull rating.
	Low hydraulic system pressure	Check pressure. Refer to Hydraulic Systems per-
		formance charts page 7.
WINCH RUNS TOO SLOW	Low hydraulic system flow rate	Check flow rate. Refer to Systerm Requirements and
		Typical Layout page 7.
	Motor worn out	Replace motor

DRUM WILL NOT	Clutch not disengaged. Check Adjustment of Manual
FREESPOOL	Shifter, page 9.
	Winch not mounted squarely, causing end bearing
	to bind up
	Side mounted bolts too long, causing binding of ring
	gear (Item #15, page 14).

Check Operation, page 5.

Check mounting. Refer to Winch Mounting, page 4.

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.

LOAD DRIFTS	Brake needs adjusting	Adjust brake. see Page 6.
CABLE BIRDNESTS WHEN	Drag screw improperly adjusted	Adjust nylon drag screw. Refer to Cable Installation,
CLUTCH IS DISENGAGED		page 4.
EXCESSIVE NOISE	Hydraulic system flow too high	Check flow rate. Refer to Typical Layout page 7.
	Brake Torque too high	Reduce torque. Refer to page 6.
	Brake oil level low.	Check oil level, add oil if necessary.
	Drum in bind, winch not mounted squarely	Check mounting. Refer to Winch Mounting, page 4.
DRUM CHATTERS IN	Low hydraulic system flow rate	Check flow rate. Refer to Typical Layout page 7.
“REEL IN” DIRECTION
	Low hydraulic system relief pressure setting	Check relief valve setting.

8

INSTRUCTIONS FOR OVERHAUL RPH-8000 SERIES WINCH

Take note of mounting configurations for proper mounting of parts during re-assembly. Replace all gaskets, o-rings, and seals during re-assembly.

35

	Remove breather plug and reducer (item #34 and #39) from
	winch. Drain oil from winch by removing plug (item #40).
	Remove motor (item #35), coupling (item #31) from winch
	by unscrewing capscrews (item #24). If coupling is being	24
	replaced, be sure pin (item #41) is installed. Tap motor lightly
	to disengage. Replace all o-rings and seals with new ones	30
	during re-assembly (order kit #246042). If necessary, remove
	valve (item #49) from motor by removing lockwashers (item
	#52) and capscrews (item #21).	49
		21

24

30

7

41

34 39

38

31

40

		7	13
	Remove tie plates (item #13) from end bearings (items #7 &		18
	#8) by unscrewing capscrews (item #18), as shown. Slide
	motor end bearing (item #7) from drum (item #1) and drum
	from gear housing end bearing (item #8). Remove input shaft
	(item #12) from end bearing. Inspect teeth of gear (item #5)		50 47
	for signs of wear. If necessary replace gear by removing snap
		13	12
	ring (item #47) and thrust washer (item #50). Slide new		8
	gear over splines of shaft and against snap ring on shaft. Re-		1
	install thrust washer and place snap ring into groove of shaft. 18
			5

9

Remove brake housing (item #9) from end bearing (item #8) by unscrewing (4) capscrews (item #23). Remove plate (item #12) and light assembly, if present. Remove gasket (item #33), coil spring (item #48), flat spring (item 3), retainer plate (item #11), composition brake discs (item #32) and cam plate (item #4). Remove hub (item #10) with plug (item #42) – which is press-fitted in the hub I.D. (Inside Diameter). Inspect the seal (item #37), inside of gear housing bore, and replace if necessary.

Inspect brake discs. Discs are 1/4" thick when new, replace if thinner than .200 inch thick or if surfaces are glazed or burnt. Inspect the flat ground surfaces of the cam plate and retainer plate for glazing, warpage or other damage. Glazing can be removed by scraping carefully. Inspect flat spring. It should be bowed at least 1/8". Replace spring if bowed less than 1/8".

		19	28
	17
			44
	29		23
9
	33		48
11			3

32

4

	51	42	46
			12
		14

10

12 32

37 45

2

8

NUT

CLUTCH ENGAGEMENT INDICATOR

LIGHT ASSEMBLY

52

45

Replace all worm or damaged parts as needed. Re-assemble all parts as shown. Be sure balls are secure between cam plate and hub.

Install brake housing, making sure that ends of capscrews (item #17) go through notches in end of flat springs and holes in the retainer plate. Secure brake housing and plate (item #12), if present, to end bearing using capscrews (item #23). Tighten capscrews to 30-40 ft-lbs.

INDICATOR LIGHT ASSEMBLY

If light is not functioning, remove light (item #2) and apply 12V DC (+) to test. If necessary, remove the switch (item #52). The terminals are normally closed. With ball depressed, the switch should be open. Replace light and/or switch, as needed.

Remove o-ring (item #36) and bushing (item		SLOT IN RING GEAR
#15) from motor end bearing (item #7). Press
	45	6
new bushing onto end bearing and dip o-ring in
oil and seat into groove of end bearing. Remove	7		8
seal (item #45) from gear housing end bearing
		16
(item #8). Loosen nut (item #27) and remove			CLUTCH
nylon setscrew (item #22) and remove ring			SHIFTER HOLE
gear (item #6) from gear housing end bearing,
if necessary. Remove bushing (item #16) from		22
gear housing end bearing (item #8). Press new
bushing (item #16) into place in end bearing.		27
Install ring gear and nylon setscrew and nut.
	15	36
Ring gear must be fully seated in gear housing

end bearing (item #8) and slot in ring gear

must NOT be aligned with clutch shifter hole. Install new seal in gear housing end bearing, with sharp edge of seal outward.

Generously apply grease (MOBILITH SHC 007) to teeth of ring gear (item #6), teeth of planet gears in drum (item #1) and to bushing in end bearings (items #7 & #8). Apply grease to teeth of gear (item #5) and to splines of shaft (item #12). Place splined end of shaft into splines of hub in brake housing end bearing (item #8). Place drum over shaft and rotate drum to engage planet gears with output gear on shaft and ring gear in end bearing.

Assemble end bearing to drum assembly and use tie plates (item #13) and capscrews (item #18) to hold both end bearings together. Tighten capscrews to 55 ft-lbs. (75 Nm.).

10

If necessary, remove and replace the shifter assembly (manual, item #2, or air-cylinder, item #3), as follows:

MANUAL CLUTCH SHIFTER ASSEMBLY

Remove by loosening setscrew (item
#25), jam nut and unscrewing clutch				HANDLE (HORIZONTAL)
shifter. Be sure slot in ring gear is not
aligned with clutch shifter hole.	13	7/16	+0
Rotate drum, if necessary, to insure			-1/16
	7
hole and slot are not aligned. Re-install	18		CYLINDER
clutch shifter with plunger, jam nut and
handle positioned in cylinder housing,			MANUAL CLUTCH ADJUSTMENT
as shown. Thread assembly (with
handle engaged in cylinder slot) into
the end bearing. Pull drum toward the	12		25
brake housing end bearing to remove
	13		8
play.	1			PLUNGER ASSEMBLY
Hold drum in the position and continue	18
		5		JAM NUT
threading the shifter assembly in until	PLANET GEARS
the gap between the end of the handle				SETSCREW
and cylinder is 7/16 +0 -1/18 inch				BLOCKED CLUTCH
	PLUNGER		2	MANUAL CLUTCH
and handle is in the horizontal posi-
	49			SHIFTER
tion, as shown below. NOTE: This gap
will vary with drum endplay. With the	AIR-CYLINDER		JAM NUT
drum pulled against the gear housing,			3
	CLUTCH SHIFTER
the gap should be 7/16 inch. Lightly
tighten jam nut.

Rotate drum until handle snaps fully into the engaged position. Pull handle out and rotate 90º. Verify that drum can be rotated freely (at least one full revolution) with clutch shifter at DISENGAGED position. Securely tighten jam nut while holding the handle.

Tighten setscrew securely. Re-check clutch operation as described on Page 5.

AIR CYLINDER SHIFTER ASSEMBLY

Remove by loosening setscrew (item #25), jam nut and unscrewing clutch shifter. To reinstall, thread air cylinder into housing. Install one or two shims (item #49) under cylinder head, if needed, to orient air cylinder port for pneumatic connections. Tighten setscrew. Refer to Page 5 and check for proper operation of the clutch.

BLOCKED CLUTCH

Insert plunger assembly into gear housing bore so it engages into ring gear slot. Pull drum flange toward gear housing and thread setscrew into housing until it bottoms out and drum starts to move. Back setscrew out 1/2 turn and lock in place with jam nut.

Before installing motor, check brake adjustment (refer to Page 7, ADJUSTING THE BRAKE).

Place splined end of coupling (item #31), with spirol pin (item
#41) installed, inside of motor end bearing housing (item #7)	35

and slide over splines on end of input shaft. Place o-ring (item #38) around motor pilot. Mount motor (item #35) to end bearing by aligning key on motor shaft with keyway in coupling. Be sure that motor mounts flush to end bearing and that

o-ring is set securely in place between motor and end bearing. 24 Secure motor to end bearing using two capscrews and lock-

washers (items #24 & #30). Tighten capscrews to 49 ft-lbs.	30
(66 Nm.). Thread plug (item #40) into bottom of brake hous-
ing. Permatex can be added to threads of plug to help in seal-
ing.

38

31

24

30

KEY

7

41

34 39

40

OIL LEVEL HOLE

40

Pour mixture of 1/2 pint (8 ounces) of Mobilfluid 424, Phillips HG Fluid, Texaco TDH, Shell Oil Company Donax TD high per-

formance tractor transmission fluid, or equivalent, and 1/4 ounce of an oil additive (available from the factory) into oil level hole. Oil level should be kept at oil level hole (plus or minus 1/8"). Thread plug (item #40) into oil level hole. Insert reducer (item 339) into hole in top of brake housing and breather plug (item #34) into reducer. Tighten plugs and reducer securely.

11

	DIM.	RPH-8,000-S	RPH-8,000-Y
	LETTER	("STD." DRUM)	("Y" DRUM)
	A	9.75	6.50
		247,6	165,1.
	*B	12.25	9.00
		311,1	228,6.
	C	26.53	23.28
		673,9	591.3

MOTOR/COUNTERBALANCE

VALVE MAY BE MOUNTED

WITH PORTS UP

		CLUTCH DISENGAGED POSITION												FOR SIDE MOUNT
.500-13UNC X .75 (INCHES) DEEP		CLUTCH ENGAGED POSITION												INSTALLATIONS, MOVE
														TIEPLATES TO FEET.
TAPPED HOLE (TYP. 2 PLACES EACH
								9.36
SIDE OF MOTOR END BEARING)
1.25	A	7.17	.50	4.68			237.7
31.8		182.1	12.7	118.9
.50 IN. (12,7MM) DIA.				2.21
				56.1
	CABLE HOLE
8.25	FLANGE DIA.
209.6															*
									E Y		IN
12							S								.56
					A	M				W						(TYP.)
				R						A			C		14.2
						C	O		M P		Y
										N			H
3.79						TU				LS A		,	A		*1.12		(TYP.)
				O								M			28.4
						K
							L
96,3									AHO
	3.94
	100.0
BARREL DIA.
3.39	B			4.19								*2.25		*1.12	(TYP.)
86.1				106.4								57.2		28.4
6.75					8.38					(TYP.)
171.5	C
				212.9

.875-14 SAE PORT	.500-13UNC X .50 (INCHES) DEEP
(TYP. 2 PLACES)	TAPPED HOLE (TYP. 2 PLACES EACH
	SIDE OF GEAR HOUSING END BEARING)

.500-13UNC X .75 (INCHES) DEEP TAPPED HOLE (TYP. 4 PLACES EACH END BEARING)

MODEL RPH 8,000

DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS

WINCH MOUNTING CAPSCREWS MUST MEET OR EXCEED SAE GRADE 5 SPECIFICATION

WITH MANUAL CLUTCH SHIFTER

*NOTE: THESE HOLE LOCATIONS MUST BE HELD WITHIN ±.03" (0.8 MM) OF

TRUE POSITION. RECOMMENDED MOUNTING HOLE DIAMETER IS .53" (13.5 MM).

13

	DIM.	RPH-8,000-S	RPH-8,000-Y
	LETTER	("STD." DRUM)	("Y" DRUM)
	A	9.75	6.50
		247,6	165,.1
	* B	12.25	9.00
		311,1	228,.6
	C	26.53	23.28
		673,9	591,3

MOTOR/COUNTERBALANCE

VALVE MAY BE MOUNTED

WITH PORTS UP.

.500-13UNC X .75 (INCHES) DEEP TAPPED HOLE (TYP. 2 PLACES EACH SIDE OF MOTOR END BEARING)

1.25	A
31,8

.50 IN. (12,7) DIA. CABLE HOLE

8.25

209,6 FLANGE DIA.

3.79

96,3

3.94

100,0 BARREL DIA.

ATTACH TO GROUND (SEE ELECTRICAL SCHEMATIC)

5.84

148,3

ATTACH TO 12V DC (+)

(SEE ELECTRICAL SCHEMATIC)

			9.36
4.68			237,7
118,9
2.21
56,1
			TC	H	EN
						G
							A
			U				G
			L				E
			C				D
			*				*
			W			L	IT
			H
				EN
		M	S	E Y			IN
					A			C
	A					W
R			O	M P			Y
		C				N		H

FOR SIDE MOUNT INSTALLATIONS, MOVE TIEPLATES TO FEET.

SWITCH

INDICATOR

LIGHT

*

14,2.56 (TYP.)

TU		LS A	,	A	*1.12	(TYP.)
O			M		28,4
K
L
	AHO

3.39

86,1

6.75

171.5

.875-14 SAE PORT (TYP. 2 PLACES)

** CAUTION: PRESSURE MUST NOT EXCEED 150 PSI.

B

C

.125-27NPT PORT

(CONNECT 80 TO 150 PSI** PRESSURE LINE TO DISENGAGE

CLUTCH.)

.500-13UNC X .50 (INCHES) DEEP TAPPED HOLE (TYP. 2 PLACES EACH SIDE OF GEAR HOUSING END BEARING)

4.19	*2.25	*1.12	(TYP.)
106,4	57,2	28,4
	8.38 (TYP.)

212,9

.500-13UNC X .75 (INCHES) DEEP TAPPED HOLE (TYP. 4 PLACES EACH END BEARING)

DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS

WINCH MOUNTING CAPSCREWS MUST MEET OR EXCEED SAE GRADE 5 SPECIFICATION

*NOTE: THESE HOLE LOCATIONS MUST BE HELD WITHIN ±.03" (0.8 MM) OF TRUE POSITION. RECOMMENDED MOUNTING HOLE DIAMETER IS .53" (13.5 MM).

MODEL RPH 8,000

ATTACH TO GROUND (16 GA.	BUTT
WIRE SUPPLIED BY CUSTOMER)	CONNECTOR
	_
12V BATTERY
	+
	SWITCH

ATTACH TO PTO INDICATOR SWITCH TO

RECEIVE 12V DC WHEN PTO IS ENGAGED.

NOTE: LIGHT SHOULD BE "ON" WHEN CLUTCH IS ENGAGED AND "OFF" WHEN CLUTCH IS DISENGAGED.

INDICATOR LIGHT (ON WHEN CLUTCH IS ENGAGED)

ELECTRICAL SCHEMATIC

WITH AIR-CYLINDER CLUTCH SHIFTER

14

		24	18
	41	30
35		38	13
			31
24
30			36
49	21
52		7	15

6

13				43	46	25	8
			1
18			50				20
	12							4
							10
				45
	47
		5	47	37				3
							51
				17
			22				42	11
				27		32
							14
MODEL RPH 8,000				2			32
								48
WITH MANUAL CLUTCH SHIFTER								33
								26

23

34

39

40

9

19

44 28

29

17

PARTS LIST - MANUAL SHIFT

15

Item No.	Quantity	Part No.	Description		Item No.	Quantity	Part No.	Description
1	1	234165	DRUM Assembly "Y"		26	2	418034	NUT 3/8-16NC HEX.REG.
	1	234166	DRUM Assembly "Standard"		27	1	418036	NUT 3/8-16NC HEX. JAM
2	1	276048	SHIFTER Assembly		28	1	418061	NUT-1/2-13NC HEX. JAM
3	1	306035	SPRING-FLAT, BRAKE		29	4	418184	WASHER-3/8 ID X 5/8 OD X 1/16 FLAT ALUM
4	1	314017	CAM PLATE-”A” ROTATION		30	2	418218	LOCKWASHER-1/2 I.D. MED. SECT.
	1	314018	CAM PLATE-”B” ROTATION		31	1	431014	COUPLING-HYD. MOTOR
5	1	334174	GEAR-OUTPUT, SUN		32	2	438018	PLATE-BRAKE
6	1	444084	GEAR-RING		33	1	442212	GASKET-Brake Housing
7	1	338326	END BEARING-MOTOR		34	1	456008	RELIEF FITTING
8	1	338327	HOUSING-GEAR, END BEARING		35	1	458074	MOTOR-HYD. (FOR MODEL WITH COUNTERBALANCE VALVE)
9	1	338328	HOUSING-BRAKE			1	458075	MOTOR-HYD. (FOR MODEL WITHOUT COUNTERBALANCE VALVE)
10	1	314019	HUB PLATE		36	1	462046	O-RING
11	1	352021	RETAINER PLATE		37	2	462047	QUAD-RING
12	1	357489	SHAFT-INPUT "Y"		38	1	462048	O-RING
	1	357490	SHAFT-INPUT " Standard"		39	1	468002	REDUCER
13	2	395163	TIE PLATE "Y"		40	2	468018	PIPE PLUG
	2	395172	TIE PLATE " Standard"		41	1	470033	SPIROL PIN
14	3	400007	BALL		42	1	472051	PLUG
15	1	412084	BUSHING-DRUM, MOTOR END		43	1	472052	PLUG
16	1	412085	BUSHING-DRUM, GEAR		44	1	486076	SEAL
17	2	414273	BOLT-3/8-16NC X 1-3/4" LG, Hexhead, GR. 5		45	1	486080	SEAL-GEAR HSG.
18	8	414581	CAPSCREW-1/2-13NC X 3/4" LG. Hexhead, GR. 5, zinc		46	1	518037	SHIM
19	1	414622	BOLT-1/2-13NC X 2-1/4" LG, Hexhead, GR. 5, ALL-THD.		47	2	490003	SNAP RING
20	2	414836	CAPSCREW-1/4-20NC X 1/2" LG, Hex Socket head		48	1	494010	SPRING
21	4	414159	CAPSCREW-5/16-18NC X 2-1/2" LG, HexheadGR5 zinc		49	1	516008	VALVE-COUNTERBALANCE ("A" ROTATION)
22	1	414926	SETSCREW-3/8-16NC X 1" LG, Sockethead, NYLON			1	516009	VALVE-COUNTERBALANCE ("B" ROTATION)
23	4	414934	CAPSCREW-3/8-16NC X 2-3/4" LG, Hex sockethead		50	1	518047	WASHER-THRUST
24	2	414952	CAPSCREW-1/2-13NC X 1-1/2" LG, Hex sockethead		51	1	340077	BRAKE SHAFT
25	1	416016	SETSCREW-1/4-20NC X 1/4" LG Hex sockethead.		52	4	418163	LOCKWASHER - 5/16 MED SECT zinc

16

	26		20
		32
37		43		15
			33
26
32			38
52
	40	8	17
										46
								51
						7	45
15								27	9
					1
20					54				22	5
			14						11
					48
			50							4
				6	50	39
									54
					24	18			44	13
					29			34
									16
MODEL RPH 8,000							3		34
										50
WITH MANUAL CLUTCH SHIFTER AND										35
CLUTCH ENGAGEMENT INDICATOR LIGHT										28

12

2

36

41

42

10

21

47 30

25

31

19

PARTS LIST - MANUAL SHIFT AND CLUTCH ENGAGEMENT LIGHT

17

Item No.	Quantity	Part No.	Description		Item No.	Quantity	Part No.	Description
1	1	234165	DRUM ASSEMBLY "Y"		27	1	416016	SETSCREW-1/4-20NC X 1/4" LG HX. sockethead
	1	234166	DRUM ASSEMBLY "STANDARD"		28	2	418034	NUT 3/8-16NC HEX.REG.
2	1	236020	LIGHT ASSEMBLY		29	1	418036	NUT 3/8-16NC HEX. JAM
3	1	276048	SHIFTER ASSEMBLY		30	1	418061	NUT-1/2-13NC HEX. JAM
4	1	306035	SPRING-FLAT, BRAKE		31	4	418184	WASHER-3/8 I.D. X 5/8 O.D. X 1/16 FLAT ALUM
5	1	314017	CAM PLATE-"A" ROTATION		32	2	418218	LOCKWASHER-1/2 I.D. MED. SECT.
	1	314018	CAM PLATE-"B" ROTATION		33	1	431014	COUPLING-HYD. MOTOR
6	1	334174	GEAR-OUTPUT, SUN		34	2	438018	PLATE-BRAKE
7	1	444084	GEAR-RING		35	1	442212	GASKET-Brake Housing
8	1	338326	END BEARING-MOTOR		36	1	456008	RELIEF FITTING
9	1	338327	HOUSING-GEAR, END BEARING		37	1	458074	MOTOR-HYD. (FOR MODEL WITH COUNTERBALANCE VALVE)
10	1	338328	HOUSING-BRAKE			1	458075	MOTOR-HYD. (FOR MODEL WITHOUT COUNTERBALANCE VALVE)
11	1	314019	HUB PLATE		38	1	462046	O-RING
12	1	350598	PLATE-LIGHT Mounting		39	2	462047	QUAD-RING
13	1	352021	RETAINER PLATE		40	1	462048	O-RING
14	1	357489	SHAFT-INPUT "Y"		41	1	468002	REDUCER
	1	357490	SHAFT-INPUT "STANDARD"		42	2	468018	PIPE PLUG
15	2	395163	TIE PLATE "Y"		43	1	470033	SPIROL PIN
	2	395172	TIE PLATE "STANDARD"		*44	1	472051	PLUG
16	3	400007	BALL		45	1	482013	GROMMET
17	1	412084	BUSHING-DRUM, MOTOR END		46	1	482045	RUBBER BOOT
18	1	412085	BUSHING-DRUM, GEAR		47	1	486076	SEAL
19	2	414273	BOLT-3/8-16NC X 1-3/4" LG, Hexhead, GR. 5		48	1	486080	SEAL-GEAR HSG.
20	8	414581	CAPSCREW-1/2-13NC X 3/4" LG Hexhead, GR. 5, zinc		49	2	490003	SNAP RING
21	1	414622	BOLT-1/2-13NC X 2-1/4" LG, Hexhead, GR. 5, all-thread.		50	1	494010	SPRING
22	2	414836	CAPSCREW-1/4-20NC X 1/2" LG, Hex sockethead		51	1	504021	SWITCH ASSEMBLY
23	4	414159	CAPSCREW-5/16-18NC X 2-1/2" LG, Hexhead GR5 zinc		52	1	516008	VALVE-COUNTERBALANCE ("A" ROTATION)
24	1	414926	SETSCREW-3/8-16NC X 1" LG, SOCKET, NYLON			1	516009	VALVE-COUNTERBALANCE ("B" ROTATION)
25	4	414934	CAPSCREW-3/8-16NC X 2-3/4" LG, Hex sockethead		53	1	518047	WASHER-THRUST
26	2	414952	CAPSCREW-1/2-13NC X 1-1/2" LG, sockethead		54	1	340077	SHAFT - BRAKE
					55	4	418163	LOCKWASHER - 5/16 MED SECT zinc

18

	26
	32		20
		43
37		33		15
26
32			38
	53											(ALT.) 12
	23
56	40	8	17
											46
									52
							7	45
												12
	15								27
										9		2
					1
	20				54					22
			14							11	5
						48
			50
				6	50		39				4
										55
							18				36
					24					44
											13
						29
									34		41
												42
									16
							49				10
										34		21
									3	51		31
										35	28	19
											47	30
											25

PARTS LIST - AIR SHIFT

19

Item	Quantity	Part No.	Description		Item	Quantity	Part No.	Description
No.					No.
1	1	234165	DRUM ASSEMBLY "Y"		27	1	416016	SETSCREW-1/4-20NC X 1/4" LG HX. sockethead .
	1	234166	DRUM ASSEMBLY "STANDARD"		28	2	418034	NUT 3/8-16NC HEX.REG.
2	1	236020	LIGHT ASSEMBLY		29	1	418036	NUT 3/8-16NC HEX. JAM
3	1	276058	SHIFTER ASSEMBLY-AIR		30	1	418061	NUT-1/2-13NC HEX. JAM
4	1	306035	SPRING-FLAT, BRK.		31	4	418184	WASHER-3/8 I.D. X 5/8 O.D. X 1/16 FLAT ALUM
5	1	314017	CAM PLATE-"A" ROTATION		32	2	418218	LOCKWASHER-1/2 I.D. MED. SECT.
	1	314018	CAM PLATE-"B" ROTATION		33	1	431014	COUPLING-HYD. MOTOR
6	1	334174	GEAR-OUTPUT, SUN		34	2	438018	PLATE-BRAKE
7	1	444084	GEAR-RING		35	1	442212	GASKET-Brake Housing
8	1	338326	END BEARING-MOTOR		36	1	456008	RELIEF FITTING
9	1	338327	HOUSING-GEAR, END BEARING		37	1	458074	MOTOR-HYD. (FOR MODEL WITH COUNTERBALANCE VALVE)
10	1	338328	HOUSING-BRAKE			1	458075	MOTOR-HYD. (FOR MODEL WITHOUT COUNTERBALANCE VALVE)
11	1	314019	HUB-PLATE		38	1	462046	O-RING
12	1	350598	PLATE-LIGHT Mounting		39	2	462047	QUAD-RING
		408191	PLATE-LIGHT Mounting (Alt.)		40	1	462048	O-RING
13	1	352021	RETAINER PLATE		41	1	468002	REDUCER
14	1	357489	SHAFT-INPUT "Y"		42	2	468018	PIPE PLUG
	1	357490	SHAFT-INPUT "STANDARD"		43	1	470033	SPIROL PIN
15	2	395163	TIE PLATE "Y"		44	1	472051	PLUG
	2	395172	TIE PLATE "STANDARD"		45	1	482013	GROMMET
16	3	400007	BALL		46	1	482045	RUBBER BOOT
17	1	412084	BUSHING-DRUM, MOTOR END		47	1	486076	SEAL
18	1	412085	BUSHING-DRUM, GEAR		48	1	486080	SEAL-GEAR HSG.
19	2	414273	BOLT-3/8-16NC X 1-3/4" LG, hexhead, GR. 5		49	2	488007	SHIM
20	8	414581	CAPSCREW-1/2-13NC X 3/4" LG. hexheadGR. 5, zinc		50	2	490003	SNAP RING
21	1	414622	BOLT-1/2-13NC X 2-1/4" LG, hexhead , GR. 5, ALL-Thread		51	1	494010	SPRING
22	2	414836	CAPSCREW-1/4-20NC X 1/2" LG, hex sockethead		52	1	504021	SWITCH ASSEMBLY
23	4	414159	CAPSCREW-5/16-18NC X 2-1/2" LG, hexhead , GR5 zinc		53	1	516008	VALVE-COUNTERBALANCE ("A" ROTATION)
24	1	414926	SETSCREW-3/8-16NC X 1" LG, SOCKET, NYLON			1	516009	VALVE-COUNTERBALANCE ("B" ROTATION)
25	4	414934	CAPSCREW-3/8-16NC X 2-3/4" LG, hex sockethead		54	1	518047	WASHER-THRUST
26	2	414952	CAPSCREW-1/2-13NC X 1-1/2" LG, sockethead		55	1	340077	SHAFT - BRAKE
					56	4	418163	LOCKWASHER 5/16 MED SECT zinc

20

		23	18
	42	31
36		39	13
			32

23

31	37
	7
	15
				6
13				44	47	24	8
		1
18			50				20
	12							4
	48			46			10
		5	48	38				3
			21	16			51	11
							43
				27
						32
				2			14
MODEL RPH 8,000				25			33	49
						29
WITH BLOCKED CLUTCH								34
								26

35

40

41

9

19

30

17

45 28

22

PARTS LIST - BLOCKED CLUTCH

21

Item No.	Quantity	Part No.	Description		Item No.	Quantity	Part No.	Description
1	1	234166	DRUM ASSEMBLY "STANDARD"		26	2	418034	NUT 3/8-16NC HEX.REG.
2	1	299693	PLUNGER ASSY.		27	1	418036	NUT 3/8-16NC HEX. JAM
3	1	306035	SPRING-FLAT, Brake		28	1	418061	NUT-1/2-13NC HEX. JAM
4	1	314017	CAM PLATE-"A" ROTATION		29	1	418088	NUT-JAM 5/8-18NF HX Z/P
	1	314018	CAM PLATE-"B" ROTATION		30	4	418184	WASHER-3/8 I.D. X 5/8 O.D. X 1/16 FLAT ALUM
5	1	334174	GEAR-OUTPUT, SUN		31	2	418218	LOCKWASHER-1/2 I.D. MED. SECT.
6	1	444084	GEAR-RING		32	1	431014	COUPLING-HYD. MOTOR
7	1	338326	END BEARING-MOTOR		33	2	438018	PLATE-BRAKE
8	1	338327	HOUSING-GEAR, END BEARING		34	1	442212	GASKET-Brake Housing
9	1	338328	HOUSING-BRAKE		35	1	456008	RELIEF FITTING
10	1	314019	HUB-PLATE		36	1	458075	MOTOR-HYD. (FOR MODEL WITH COUNTERBALANCE VALVE)
11	1	352021	RETAINER PLATE		37	1	462046	O-RING
12	1	357490	SHAFT-INPUT		38	2	462047	QUAD-RING
13	2	395172	TIE PLATE		39	1	462048	O-RING
14	3	400007	BALL		40	1	468002	REDUCER
15	1	412084	BUSHING-DRUM, MOTOR END		41	2	468018	PIPE PLUG
16	1	412085	BUSHING-DRUM, GEAR		42	1	470033	SPIROL PIN
17	2	414273	BOLT-3/8-16NC X 1-3/4" LG, hexhead GR. 5		43	1	472051	PLUG
18	8	414581	CAPSCREW-1/2-13NC X 3/4" LG. hexhead GR. 5, zinc		44	1	472052	PLUG
19	1	414622	BOLT-1/2-13NC X 2-1/4" LG, hexhead, GR. 5, ALL-Thread		45	1	486076	SEAL
20	2	414836	CAPSCREW-1/4-20NC X 1/2" LG, hex sockethead		46	1	486080	SEAL-GEAR HSG.
21	4	414159	CAPSCREW-5/16-18NC X 2-1/2" LG, HX. HD., GR5 Z/P		47	1	518037	SHIM
22	1	414926	SETSCREW-3/8-16NC X 1" LG, SOCKET, NYLON		48	2	490003	SNAP RING
23	4	414934	CAPSCREW-3/8-16NC X 2-3/4" LG, hex sockethead		49	1	494010	SPRING
24	2	414952	CAPSCREW-1/2-13NC X 1-1/2" LG, sockethead		50	1	518047	WASHER-THRUST
25	1	416016	SETSCREW-1/4-20NC X 1/4" LG hex sockethead		51	1	340077	SHAFT - BRAKE

MANUEL D’UTILISATION,

DE DÉPANNAGE

ET D’ENTRETIEN

TREUIL À PLANÉTAIRE MODÈLE RPH-8000

MISE EN GARDE : ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE CE MANUEL AVANT D’INSTALLER ET D’UTILISER LE TREUIL. N’OUBLIEZ PAS LES AVERTISSEMENTS ET MISES EN GARDE.

Ramsey Winch Company

P.O. Box 581510 - Tulsa, OK 74158-1510 USA

Phone: [phone] - Fax [phone]

Visit us at http://www.ramsey.com

TABLE DES MATIÈRES

INTRODUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 INFORMATIONS DE GARANTIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 CARACTÉRISTIQUES TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 AVERTISSEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 FIXATION DU TREUIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 INSTALLATION DU CÂBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 ENTRETIEN DU TREUIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 FONCTIONNEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 RÉGLAGE DU FREIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 SYSTÈMES HYDRAULIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 MONTAGE HYDRAULIQUE TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 DIAGRAMMES DE PERFORMANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 GUIDE DE RÉSOLUTION DES PROBLÈMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 INSTRUCTIONS DE RÉVISION DES TREUILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-32 PLAN COTÉ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-34 LISTE ET SCHÉMA DES PIÈCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35-42

GARANTIE LIMITÉE

RAMSEY WINCH garantit chaque treuil RAMSEY neuf contre tout défaut de matériau et de fabrication pendant une période d’un (1) an à partir de la date d’achat. L'obligation aux termes de cette garantie, statutaire ou autre, est limitée au remplacement ou à la réparation à l’u- sine du fabricant, ou à un endroit désigné par le fabricant, de la pièce qui semblera présenter un défaut de fabrication ou de matériau, suite à l'inspection effectuée par le fabricant.

Cette garantie n’oblige pas RAMSEY WINCH à s’acquitter des frais de main-d'ouvre ou de transport liés au remplacement ou à la réparation des pièces défectueuses, et ne s'applique pas à un produit ayant subi des réparations ou des modifications (sauf si elles ont été autorisées par le fabricant), ou en cas de mauvaise utilisation de l’équipement, de négligence ou de matériel mal installé.

RAMSEY WINCH ne pourra en aucun cas être tenue responsable des dommages particuliers et indirects. RAMSEY WINCH n’émet aucune garantie au sujet des accessoires et portant par exemple sur les garanties de leurs fabricants respectifs. RAMSEY WINCH s’efforce de poursuivre une politique d’amélioration constante et se réserve par conséquent le droit d'améliorer ses produits par le biais de modifications de leur conception ou des matériaux employés, selon les besoins, et sans être obligée d'incorporer ces modifications aux produits fabriqués précédemment.

En cas d’intervention sur le terrain à la demande de l’acquéreur, et si la défaillance s’avère ne pas provenir du produit RAMSEY WINCH, l’acquéreur s’engage à s’acquitter auprès du représentant des frais correspondant au temps et aux dépenses.

Les factures d'entretien, de main-d’ouvre et autres frais engagés par l’acquéreur sans l'accord ou l'autorisation de RAMSEY WINCH ne seront pas acceptées.

Reportez-vous à la carte de garantie pour les détails.

VEUILLEZ LIRE ATTENTIVEMENT CE MANUEL.

Ce manuel contient des conseils utiles pour l'utilisation efficace de votre treuil Ramsey ; il aborde aussi les procédures de sécurité à connaître absolument avant l’utilisation d’un tel équipement.

INFORMATIONS DE GARANTIE

Les treuils Ramsey sont conçus et fabriqués selon des spécifications rigoureuses. Ils font tous l’objet d’un travail soigné et compétent. En cas de besoin, la procédure de recours en garantie est détaillée au verso de votre carte de garantie préadressée à port payé. Veuillez lire et remplir la carte de garantie ci-jointe, et l'envoyer à Ramsey Winch Company. En cas de problème avec votre treuil, suivez les instructions fournies afin d’obtenir un service rapide de recours en garantie.

*CARACTÉRISTIQUES TECHNIQUES

Traction du câble	(lbs.)	…………………………………………………				8,000
nominale	(Kg.)	…………………………………………………				3,620
Démultiplication	……………………………………………………………					5.1:1
Poids (sans le câble)		RPH-8000 STD. ……..…....………. 90 lbs. (40.9 Kg)
		RPH-8000 "Y" ………….………….. 85 lbs. (38.6 Kg)
Couche de câble		1	2	3	4	5
*Traction Nominale	lbs.	8,000	6,800	5,900	5,200	4,700
Par Couche De Câble	Kg.	3,620	3,080	2,670	2,350	2,120
* Capacité De Câble Par Couche
RPH-8000 (STD.	ft.	25	55	90	130	170
DRUM)	m	7	16	27	39	51
RPH-8000 ("Y"	ft.	15	35	60	85	115
DRUM)	m	4	10	18	25	34
* Vitesse du câble	FPM	50	58	67	76	84
(à 56 l/min)	MPM	15.2	17.6	20.3	23.1	25.5

*Ces caractéristiques techniques sont basées sur un câble d’aéronef galvanisé de 10 mm ou sur un câble en acier de charrue amélioré et sur un moteur de 254 cm³/tr.

Remarque : les tractions nominales indiquées sont uniquement pour le treuil. Consultez le fabricant du câble pour les caractéristiques nominales de ce dernier.

AVERTISSEMENTS :

L’EMBRAYAGE DOIT ÊTRE ENTIÈREMENT ENCLENCHÉ AVANT DE COMMENCER TOUT TREUILLAGE.

NE RELÂCHEZ JAMAIS L’EMBRAYAGE EN PRÉSENCE D’UNE CHARGE.

NE LAISSEZ PAS L’EMBRAYAGE ENCLENCHÉ LORSQUE LE TREUIL N’EST PAS UTILISÉ.

NE VOUS PLACEZ JAMAIS SOUS UNE CHARGE SOULEVÉE NI À PROXIMITÉ.

RESTEZ À L’ÉCART DU CÂBLE LORS DU TREUILLAGE. N’ESSAYEZ PAS DE GUIDER LE CÂBLE.

NE DÉPASSEZ PAS LES CARACTÉRISTIQUES DE TRACTION NOMINALES MAXIMALES INDIQUÉES DANS LE TABLEAU.

N’UTILISEZ PAS LE TREUIL POUR SOULEVER, MAINTENIR OU TRANSPORTER DES PERSONNES.

IL CONVIENT DE CONSERVER AU MINIMUM CINQ TOURS DE CÂBLE AUTOUR DU TAMBOUR POUR MAINTENIR LA CHARGE. L’ATTACHE DU CÂBLE N’EST PAS CONÇUE POUR ASSURER LE MAINTIEN D’UNE CHARGE.

DANS LES APPLICATIONS DE TRANSPORT D’AUTOMOBILES, VEILLEZ À BIEN FIXER LE VÉHICULE SUR LE PORTEVOITURES. LA CHARGE IMPOSÉE AU CÂBLE DU TREUIL NE DOIT PAS ÊTRE MAINTENUE PENDANT LE TRANSPORT. N’U- TILISEZ PAS LE TREUIL COMME DISPOSITIF D’ATTACHE.

LORSQUE VOUS TREUILLEZ UNE LOURDE CHARGE, PLACEZ UNE COUVERTURE, UNE VESTE OU UNE BÂCHE SUR LE CÂBLE À ENVIRON 1,8 m DU CROCHET.

ÉVITEZ TOUS RISQUES DE GLISSEMENT DE LA CHARGE OU D’À-COUPS À SON NIVEAU, CAR ILS POURRAIENT S’AVÉRER DANGEREUX.

24

FIXATION DU TREUIL

INSTRUCTIONS DE MONTAGE IMPORTANTES POUR MAINTENIR L’ALIGNEMENT DES ÉLÉMENTS DU TREUIL À PLANÉTAIRE :

Ce treuil doit absolument être monté correctement afin que les trois principales parties soient alignées (l’extrémité du carter d’embrayage, le tambour du câble et l’extrémité de la boîte d'engrenages).

À des fins de conformité, s’il s’agit d’un montage de treuil intermédiaire, il convient de fixer au moins une plaque de serrage aux pieds de fixation au bas du treuil pour maintenir l’alignement. REMARQUE : si le treuil est installé sur pieds, au moins une plaque de serrage doit être placée au point intermédiaire pour maintenir l’alignement. Il est toujours souhaitable d’u- tiliser les deux plaques de serrage pour l’installation finale.

Il est conseillé d’utiliser le coffret de montage sur cornières, nº 251006 (pour tambour « Standard ») et nº 251007 (pour tambour « Y ») pour faciliter l’installation du treuil. Ce coffret permet de s’adapter aux installations verticales ou intermédiaires, et constitue une surface de montage droite et solide.

Si vous installez le treuil sans le coffret de cornières Ramsey recommandé, il convient alors d’utiliser les trous de fixation décrits en page 14. La surface de fixation doit être plane, à 0,38 mm près, et suffisamment rigide pour ne pas fléchir. Si une plaque d’acier est employée pour l’installation sur pied, elle doit mesurer 19 mm d’épaisseur. Pour ce type de montage, vous aurez besoin de huit vis d’assemblage 1/2-13 NC x 1,5 po de long, grade 5, avec leurs rondelles de sécurité. Ces vis devront être serrées à un couple de 115 Nm.

MISE EN GARDE : en cas d'utilisation de boulons plus longs (grade 5 minimum) pour la fixation du treuil ou d'un guide à galets au niveau des cales de fixation latérales, la longueur des boulons ne doit pas permettre un engagement des filets de moins de 12 mm dans les trous taraudés sur les côtés de chaque palier d'extrémité ( cf. page 15). Des boulons trop longs endommageraient le treuil et empêcheraient le tambour de tourner librement. Serrez les boulons à un couple de 75 Nm.

	EXTRÉMITÉ MOTEUR	TAMBOUR DU CÂBLE	EXTRÉMITÉ BOÎTE
			D'ENGRENAGES

MONTAGE SUR PIED	PLAQUE DE SERRAGE LATÉRALE

PLAQUE DE SERRAGE AU PIED (BASE)

MONTAGE INTERMÉDIAIRE

REMARQUE : si des cornières ou une plaque d’acier sont utilisées pour

l’installation du treuil, les plaques de serrage fournies doivent être fixées aux cales de montage restantes, qu’elles soient latérales ou inférieures.

INSTALLATION DU CÂBLE

Un autocollant placé sur le dessus du palier d’extrémité indique le sens de l’enroulement du câble. Les lettres « A » ou « B » figurent aussi sur le palier d’extrémité, côté frein, pour indiquer le sens de rotation. Si cet autocollant est détérioré ou illisible, contactez le service clientèle pour savoir comment déterminer le sens de rotation correct.

1.Déroulez le câble sur le sol pour éviter qu'il ne se torde. Recouvrez bien l’extrémité du câble opposée au crochet d’un ruban adhésif plastique ou de type équivalent pour éviter qu’il ne s’effiloche.

2.Placez l’extrémité effilée du câble dans le trou du tambour, comme indiqué ci-dessous. Utilisez une vis de pression à tête creuse hexagonale 3/8-16 NC x ½ po de long (sur le tambour « Y » 234165 et sur le tambour « Standard » 234166) pour fixer le câble au tambour.

3.Faites tourner avec précaution le treuil dans le sens de l’enroulement. Conservez une tension sur l’extrémité du câble et enroulez tout le câble sur le tambour en veillant à former des couches régulières.

Une fois le câble installé, vérifiez que le tambour

tourne librement. Désenclenchez l’embrayage et tirez sur le câble en marchant. Si le câble se détend et forme des boucles autour du tambour, desserrez le contre-écrou (pièce nº 27) et tournez la vis en Nylon (pièce nº 22) dans le sens des aiguilles d’une mon-

tre pour augmenter le frottement sur le tambour. Si le frottement est trop important, desserrez cette vis en

la tournant dans le sens inverse des aiguilles d’une montre. Serrez le contre-écrou une fois le réglage correct obtenu.

MISE EN GARDE : tout serrage excessif du contreécrou pourrait fausser le filet de la vis de pression en Nylon.

Sens de rotation « B »

25

SENS DE ROTATION	SENS DE ROTATION
DU TAMBOUR	DU TAMBOUR

ENTRÉE

CORRESPONDANT À L'ENROULEMENT

SENS DE ROTATION « A »

SENS DE ROTATION « B »

ENTRETIEN

1.Examinez l’état du câble et lubrifiez-le fréquemment. Tout câble effiloché ou comportant des brins brisés doit être remplacé immédiatement. Il est possible de se procurer un ensemble câble-crochet (câble de 30 mètres) nº réf. 524118 (tambour « Y ») ou (câble de 45 mètres) nº réf. 524119 (tambour « Standard ») auprès d’un distributeur Ramsey.

2.Assurez-vous que l’embrayage est complètement enclenché. Reportez-vous aux instructions de la rubrique FONCTIONNEMENT, cidessus, selon le type d’embrayage. POUR LES EMBRAYAGES MANUELS UNIQUEMENT : tous les mois, désenclenchez l'embrayage, placez plusieurs gouttes d'huile sur l'arbre et manipulez plusieurs fois l'embrayage pour lubrifier l’intérieur du cylindre.

3.Vérifiez le frein afin de vous assurer de l’absence de glissement. Reportez-vous à la page 27.

4.Assurez-vous que le câble ne se détend pas pour former de larges boucles lors du déroulement libre. Reportez-vous à la page 25.

5.Remplacez les bagues du tambour ainsi que les joints lorsqu'ils commencent à perdre de la graisse. Reportez-vous aux INSTRUCTIONS DE RÉVISIONS en page 30-32. Le cas échéant, ajoutez du lubrifiant, Mobilith SHC 007, aux engrenages.

FONCTIONNEMENT

Pour vous familiariser avec votre treuil, il est vivement conseillé de l’essayer avant de vraiment l’utiliser. Préparez votre essai à l’avance. N’oubliez pas que vous entendez votre treuil autant que vous le voyez fonctionner. Apprenez à reconnaître le son d'une traction légère et régulière, celui d'une lourde charge ou encore celui provoqué par des à-coups ou une déviation de la charge. Évitez tous risques de glissements de la charge ou d’à-coups à son niveau, car ils pourraient représenter de dangereuses conditions.

L’embrayage du treuil permet un déroulement rapide du câble, à partir du tambour, afin de le fixer à une charge. L’embrayage est actionné au moyen de sa manette ou du cylindre pneumatique.

AVERTISSEMENT : NE RELÂCHEZ JAMAIS L’EMBRAYAGE EN PRÉSENCE D’UNE CHARGE!

EMBRAYEUR MANUEL (cf. page 33)

POUR DÉSENCLENCHER L’EMBRAYAGE – Faites fonctionner le treuil dans le sens de déroulement jusqu'à ce que le câble ne tracte plus la charge. Tirez sur la poignée et tournez-la de 90º. Avec la poignée en position « DÉSENCLENCHÉE », le tambour peut désormais tourner librement.

POUR ENCLENCHER L’EMBRAYAGE – Tirez sur la poignée, faites-la tourner de 90º, puis relâchez-la. Faites fonctionner le treuil dans le sens inverse jusqu’à ce que la poignée s’enclenche en position « ENCLENCHÉE ». N’essayez PAS de treuiller une charge si la poignée n'est pas complètement « ENCLENCHÉE ». Si le témoin lumineux d’embrayage manuel est présent, la lumière verte s’allume lorsque l’embrayage est « ENCLENCHÉ ». N’essayez PAS de treuiller une charge si le témoin vert n’est pas allumé. Pour brancher ce voyant sur le système électrique du véhicule, reportez-vous au schéma de câblage de la page 34.

EMBRAYEUR À CYLINDRE PNEUMATIQUE (cf. page 34)

POUR DÉSENCLENCHER L’EMBRAYAGE – Faites fonctionner le treuil dans le sens de déroulement jusqu'à ce que le câble ne tracte plus la charge. Appliquez une pression pneumatique à l’orifice de 0,125-27 NPT de 550 kPa (minimum) à 1 030 kPa (maximum). MISE EN GARDE : la pression ne doit pas dépasser 1 030 kPa.

POUR ENCLENCHER L’EMBRAYAGE – Retirez la pression pneumatique du cylindre (un ressort de rappel enclenche le piston plongeur). Faites fonctionner le treuil dans le sens inverse jusqu'à ce que le témoin lumineux d'enclenchement de l'embrayage (voyant vert) s’allume. N’essayez PAS de treuiller une charge si le témoin vert n’est pas allumé. Pour brancher ce voyant sur le système électrique du véhicule, reportez-vous au schéma de câblage en page 34.

26