Ramsey RPH 8000T User Manual

OPERATING, SERVICE AND MAINTENANCE MANUAL

MODEL RPH 8000T

PLANETARY WINCH

INTENDED PURPOSE for RAMSEY RPH 8000T:

Vehicle Recovery and Pulling of Loads

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

RAMSEY HYDRAULIC PLANETARY WINCH MODEL RPH-8000T

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 “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 our winch, please follow instructions for prompt service on all warranty claims. Refer to back page for limited warranty.

SPECIFICATIONS*

Noise level 79 dB (A)

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 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. NOTE: If the winch is foot mounted then at 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.

Angle Mounting Kit, #251006 (“STD.” drum) and #251007 (“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 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) ½-13NC 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:

the remaining mounting pads, whether they be side or foot.

*CAUTION:

side mount pads, bolt length must be such as to allow a maximum of .50 inch thread length engagement in the tapped holes in sides of each end bearing. Refer to page 15. Use of excessive length bolts will damage the winch and prevent free spool of the drum. Torque bolts to 55-ft. lb. (75 Nm).

If angles or a steel plate are used in mounting winch, tie plates provided with winch are to be attached to

If longer bolts (minimum Grade 5) are substituted to mount winch or to mount a roller guide at the

CABLE INSTALLATION

A decal on the top of the end bearing indicates the spooling direction of the cable. Also, a letter “A” or “B” is stamped in the end bearing on the brake end indicating rotation. If the decal is damaged or unreadable, contact Customer Service for additional instructions to determine proper direction.

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 ½ lg. Hex. Soc. drive setscrew (part of 234165 “Y” drum assembly. & 234166 “STD.” 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 #27) and turn nylon screw (item #22)

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.

clockwise to increase drag on drum. If

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 (LB) first layer vs. working pressure (PSI), and (2) line speed, first layer (FPM) vs. flow (GPM). A cylinder spool directional control valve is recommended.

SYSTEM REQUIREMENTS:

2500 PSI RELIEF VALVE SETTING

15 GPM FLOW RATE*

10 MICRON NORMAL FILTRATION

1000 PSI MAXIMUM BACK PRESSURE

EMERGENCY STOP VALVE

Installer must determine type of emergency stop required.

manual control valve also serves as an emergency stop valve. An emergency stop valve may be required with other types of control valves.

*CAUTION:

PERFORMANCE

DO NOT EXCEED 20 GPM. IF EXCEEDED, MOTOR AND WINCH MAY BE DAMAGED.

CHARTS*

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 that 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 cable drum, for hooking onto the load. The clutch is operated by the clutch shifter lever or air shifter.

WARNING:

MANUAL CLUTCH SHIFTER

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 free-spooled from

drum.

TO ENGAGE CLUTCH: Pull handle out, rotate 90 o 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 hookup light to the vehicle electrical system refer to the Electrical Schematic on page 15.

AIR CYLINDER CLUTCH SHIFTER

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:

TO ENGAGE CLUTCH:

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 hookup light to the vehicle electrical system refer to the Electrical Schematic on page 15.

MAINTENANCE

Pressure must not exceed 150 PSI.

Remove air pressure from the cylinder (a return spring engages the plunger). Run

DO NOT DISENGAGE CLUTCH UNDER LOAD.

(Refer to page 14)

(Refer to page 15)

1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with broken strands, replace immediately. Cable and hook assembly P/N 524118 (“Y” drum) or 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 shaft and work clutch IN and OUT several times to lubricate inside of clutch cylinder.

3. Check brake for drift. Refer to page 7.

4. Check oil level of winch brake housing every month. Remove oil level plug (refer to pg.13). Oil level should be kept up to oil level hole (plus or minus 1/8”). Replace oil annually or more often if winch is used frequently. Use ½ pint of Mobilfluid 424, Phillips HG Fluid, Texaco TDH, Shell Oil Co. Donax TD high performance tractor transmission fluid or equivalent, and for quietest operation, add ¼ fl. oz. of an oil additive (available from the factory).

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

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

INSTRUCTIONS, page 8.

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

TROUBLE SHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION

DRUM WILL NOT ROTATE AT NO LOAD

DRUM WILL NOT ROTATE UNDER LOAD

WINCH RUNS TOO SLOW Low hydraulic system flow rate.

DRUM WILL NOT FREESPOOL Clutch not disengaged.

OIL LEAKAGE Damaged brake housing, gasket, or

OIL LEAKAGE FROM BREATHER PLUG Breather below oil level. Check oil level.

LOADS DRIFT Brake needs adjusting Adjust brake. Refer to page 7

CABLE BIRDNESTS WHEN CLUTCH IS DISENGAGED EXCESSIVE NOISE Brake torque too high.

DRUM CHATTERS IN “REEL IN” DIRECTION

Winch not mounted squarely, causing end bearings to bind up drum.

Brake damaged

Gears damaged Load greater than rated capacity of winch.

Low hydraulic system pressure.

Winch not mounted squarely, causing end bearing to bind up drum.

Motor worn out.

Winch not mounted squarely, causing end bearings to bind drum.

Side mount bolts (item #18 Page 17) too long, causing binding of ring gear.

breather.

Damaged brake hub seal.

Drag screw improperly adjusted. Adjust nylon drag screw. Refer to page

Hydraulic system flow too high.

Brake oil level low.

Drum in bind, winch not mounted squarely. Low hydraulic system flow.

Low hydraulic system relief pressure setting.

Check mounting. Refer to WINCH MOUNTING page 2.

Inspect and replace brake.

Inspect and replace damaged gears. Refer to SPECIFICATIONS page. 1 for line pull rating.

Check pressure. Refer to HYDRAULIC SYSTEMS performance charts page 4.

Check mounting. Refer to WINCH MOUNTING page 2. Check flow rate. Refer to HYDRAULIC SYSTEMS flow chart page. 4.

Replace motor. Check OPERATION. Refer to page. 5.

Check mounting. Refer to WINCH MOUNTING page. 2.

Check bolt length. Bolt thread MUST NOT engage threaded holes in sides of end bearing by more than the .50 inch thread depth in the end bearing. Refer to page 15. Replace gasket. Check for plugged breather. Refer to pages 8 & 10.

Replace seal. Refer to page 10.

3 Reduce torque. Refer to page 7.

Check flow rate. Refer to HYDRAULIC SYSTEMS flow chart page 4.

Check oil level, add oil if necessary.

Check mounting. Refer to WINCH MOUNTING page 2. Check flow rate. Refer to HYDRAULIC SYSTEMS flow chart page 4.

Check relief valve setting. Refer to HYDRAULIC SYSTEMS page 4.

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 ¼ 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” dia. straight motor shaft, with ¼” key, in a 1” hex. socket, as shown in the following figure.

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 ft. lbs. If the torque wrench does not show the proper torque value, the adjusting screw should be adjusted ¼ 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. If heating becomes noticeable when running the winch in “CABLE IN” (raising direction), the brake should be again disassembled. When disassembled, place the brake balls in the alternate set of slots in the cam plate (see View A-A page 10), then carefully follow the instructions for re-assembling and checking the brake.

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