MODEL RPH-50,000 INDUSTRIAL PLANETARY
Contents
1. 3ldvav L p SNINV38 ZLLCOV l AIM LAVHS 351 VH8 L 9 YILHIHS 14VHS v908S L 13ASV9 YOLOW L q LAVHS 6 296 L LL IMVYE L e Y4VI9 9NINV38 L OL ATEINSSSV IMVEYE 420867 L 66 YOLOW ONIHV38 L 6 YACNITAO HIY 21068 L ve L 8 5 02 9 EcOZEv L SMV 2667 L 2 06 02 91 2 GAH 9NILLIA 80267 L ce LAVHS 8076 L 9 LYASNI GvO9cr L LE d AIM 80276 L 6 HOLN19 H3OVdS 9 L 0 xog YVI9 015963 L 1109 YSCTINOHS 657817 311 860670 L t 1 ONIHdS HHHSVM 0vv8Ly L 8 all 760670 L 4 GI 886 X p L Z HOLNID H3HSVM 6evelt L 22 ATENSSSV NNYG OGLYET L L NOILdIJIS3O HLIVA ALO WALI NOIIdIJOSTO LYVd ALO Wall 0000S 1511 SLYVd 16 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 RAMSE2. 55 2 10 QD O RING s DRUM BUSHING 462043 T m ASSEMBLY 6 Remove output coupling 6 and coupling shaft 8 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 13 7 Remove 12 capscrews 15 to pull gear housing cover and gasket from ring gear 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 GEAR HOUSING SOVER f 36 14 10 RE ASSEMBLY 8 NOTE DETERMINE MOUNTING CONFIGURATION OF WINCH 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 capscr
3. 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 9 p 13 Attach motor 40 with well oiled gasket 35b to brake 35 Use 2 capscrews 20 and torque to 74 ft Ibs each Securely connect tube 46 to elbow 32 in bottom of valve 47 and fitting 33 in bottom of brake 35 40 20 35 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 438 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 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 10 38 39 __ OIL LEVEL PLUG 15 Check proper operation of clutch by applying air pressure to clutch air cylinder to disengage clutch Verify that winch freespools Re engage clu
4. 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 10 GEAR HOUSING COVER 14 Qoo RING GEAR 15 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 412 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 Ibs each in criss cross pattern 23 10 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 27 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 27 Slide 2 3 8 OD clutch washer 25 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
5. s 2d i 7 ALTERNATE CARTRIDGE LOCATION AS DESCRIBED x SYSTEM IN VIEW A A ES 3 POSITION ON PAGE 13 4 WAY VALVE MOTOR SPOOL PERFORMANCE CHARTS BASED ON 9 6 CU IN REV MOTOR 25 50 000 gt m lt gt 45 000 22 40 000 cr 15 35 000 2 30 000 di 10 25 000 a gt 20 000 5 15 000 2 10 000 0 0 1 000 2 000 3 000 0 5 10 15 20 25 WORKING PRESSURE PSI 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 00 F 180 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 cabl
6. DRUM BARREL IS NECESSARY TO HOLD THE LOAD CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD 1 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 Ib 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 amp PORT CONTROL WITH BRAKE RELEASE SHUTTLE gt CJ 9 MOTOR BRAKE S PUMP PORT E E A Y S ES e
7. 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 27 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 27 21 sf 3 8 42 B e PES APPLY LOC TITE TO SETSCREW 09 1 37 O DNG el 2 a3 INCA ds e 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 PM 20 46 35 3 Remove brake assembly screws 16 from brake 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 be
8. IA Y 4 B i 338 aaovoNa E 2 T SNIHdS SI HOLNTO cg DNIDVONSSIG la ISd 021 OL 001 LHOd E Y p JUNSSIUd LANZZ 8 1 i x 95 a vi E 3 wnua voe t 5 10 2 STL 5896 ONIGTOH 081 21 16 6 0601 14 LONGEST SPLINES my A DI 15 RPH 50 000 WINCH 10916 L 47 3201 MHL 8 L X AN 91 9 LAN og belt L ATENSSSV 38N1 L 9y 1SNYHL YIHSVM 4 SC YALNO HOLNID ONINdS vLLv6b L Sy 1938 Q3N 8 2 YIHSVAMA901 192811 8 ONIGdS 90767 L br DOS XH GT X ON 12 01 MIYJISAVO 09 7 OfTld ddid 61089p L GH DOS 91 X ON L Z L MAYOSLAS 2209Lv L 439033 700897 L 90S 91 I X 0 9 6 MAYOSLAS 9091 L LZ ONIS GAVND 0 0097 4 LV 205 91 b l L X ON El Z l MIYISAVI 4 02 AIM M OMNVYGAH HOLOMW 970857 L 07 505 911 X ON El Z l M3HOSdVO Zv6viv 4 6l 43H1V3Y49 860957 L 6 DOS XH 91 2 1 X ON91L 8 MIHDSdVO SE6bLb 8l NILLI 43138 80095 L 86 S H9 AH XH 912 X ON6 8 2 M3HOSdVO 78 77 8 ZL YIGNITAO HIY L334SV9 L 26 8 H9 XH OT X ONEL 2 L MIYJISAVO lt 6 4 9 xog YVI9 13MSVD OLcecvv 96 S H9 XH 919 MIYISAVO LSSylt cl 13MSV9 31V ld 1 4 9 LSNYHL 5 980217 L
9. OPERATING SERVICE RAMSEV AND MAINTENANCE WINCH MANUAL MODEL RPH 50 000 INDUSTRIAL PLANETARY WINCH CAUTION READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH SEE WARNINGS INTRODUCTION TABLE OF CONTENTS WARRANTY SPECIFICATIONS EEUU WARNINGS WINGH MOUNTING annie ideene CABLE INSTALLATION tet ee ted nth HYDRAULIC SYSTEM REQUIREMENTS seen PERFORMANCE CHAR TS CLUTCH OPERATION ettet tet ite teet bert ere MINA AAA Rete eese MAINTENANCE TROUBLE SHOOTING INSTRUCTIONS FOR OVERHAUL aipa tnt nieto ene MOUNTING DIMENSIONAL PARTS LIST AND PART EIMETED WARRANTY riri oi e ee EP Pen rr e ead 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 proc
10. Y 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 RAMSEV WINCH RAMSEY WINCH COMPANY Post Office Box 581510 Tulsa Oklahoma 74158 1510 Telephone 918 438 2760 FAX 918 438 6688 OM 914103 0105 E
11. aring Take note of mounting configuration for proper mounting of parts during re assembly E 35d sg 35a 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 7203 INNER MOST CAPSCREWS 1724 Y OUTER MOST CAPSCREW 017 124 29 5 Pull drum assembly 1 upward from end bearing 10 Remove quad rings 41 from grooves drum bushings Remove input shaft 11 clutch springs 44 8 45 washers 25 amp 27 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 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 41 FR O RING V 462043 S S 1 2 7 5 a BUSHING ia EN DRUM DRIVER 5 C 2 41 412078 GROOVE ty BUSHING 7412079 47 lt 44 DRE 4
12. e 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 uneven spooling of cable while pulling a load is not a problem unless there 5 a cable pileup on one end of drum If this happens reverse the winch to relieve the load and move your anchor point further to the center of the vehicle After the job is done you can unspool and rewind for a neat lay of the cable MAINTENANCE Adhering to the following maintenance schedule will keep your winch in top condition and performing as it should with a minimum of repair A WEEKLY 1 Check the oil level and maintain it to the oil level plug If oil is leaking out determine location and repair 2 Check the pressure relief plug in top of the gear housing Be sure that it is not plugged 3 Lubricate cable with light oil B MONTHLY 1 Check the winch mounting bolts If any are missing replace them and securely tighten any that are loose Use grade 5 or better bolts 2 Inspect the cable If the cable has become frayed
13. edure 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 IbS J as aannnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnunnunnunnnnnunnunnnunnnnnunnvnne 50 000 EE A OS 22 670 Gear Reduction Weight without cable LAYER OF CABLE L2 2 Rated line pull Lbs 50 000 40 900 34 600 30 000 26 400 per layer Kg 2 670 18 550 15 690 13 600 11 970 Cable capacity Line speed at 25 GPM These specifications are based on recommended wire rope of 875 inch dia extra improved plow steel or equivalent 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
14. ews 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 Ibs each Torque shoulder bolts to 30 ft lbs each Check rotation of cable drum assembly It must rotate freely with no tight spots m17 24 OUTER MOST CAPSCREW 1724 Ge INNER MOST CAPSCREWS 17 a a OUTER MOST CAPSCREW TOSS Se 4 AN 9 Place end with longest splines of output coupling assembly 6 through end bearing bushing 13 and mesh coupling spline with spline inside of drum Slide clutch spacer 430 over end and against shoulder of shifter shaft 12 Place shifter shaft through washer 24 and into shaft coupling 6 meshing splines of shifter shaft with splines in shaft coupling 10 25 10 Set gasket 36 into place on gear housing end bearing 10 Place ring gear onto end bearing 11 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 412 and mesh with teeth of input carrier Apply grease to input thrust washer and place into slots of gearbox cover Place gasket 35 into position on gearbox cover with sealer Remove 2 temporary capscrews and attach cover and
15. tch 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 CHANNEL CHANNEL SIDE SIDE ANGLE SIDE ET ANGLE SIDE R H MOUNTING L H MOUNTING CONFIGURATION CONFIGURATION WINCH MOUNTING CONFIGURATIONS 1HOd LdNZz 8 L 4861 529 NN 8202 a 0 689 erez NOILVYNSDISANOO ONILNNOW H H 000 0S Hdy 13A0N 1 dAL 1HOd 5NIH O GV3YHL LHOIVHLS IVS z1 290 1 HOLON INOYA Q3A3IA NOILVLOH INH 3ISIMMIOTO S3AI9 3HfSS3Hd HOLON INOYA AMIA NOILVLOH INNYA 3ISIMM2079 83LNNOD S3AI9 NI 3HfISS3Hd he 1 3A1VA HOLOW V V 90z 18 NOILVLOY 3LISOddO Q3SH3A3H 38 LSNIN JDAIYLYVD DN Td 40 NOILVOOT NI 318VO 1338 OL HONIM 40 YOLOW WOHJ GAM3IA SV SASIMMDO19 S31VLOH INNYA 318VO NMOHS NOILISOd NI 39dlH 1HVO ANY Sfr Td HLIM s3ov d v dAL 6 OE 9 S 315 Hova SAOV1d v dAL HOLOIN NINO 9 6 90 vid 9 oz Lg 999 Lees 8 8ez 00 osz 2902 osz 076 692 ite 6192 901 LEOL 1 y XU a KU 9 6 NOILV9O1 1HOd OLLVINNANd Y Y rue 39NV 14 n naa wnud m Sec v 90t 8 444 2 TITT 9 9 VIG a 00 91 002 d m 5 2 i 60 1HOd 40 NOLLVANSIYO e 88 1 HOS MI
16. 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 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 WINCH Seals damaged or worn OIL LEAKS FROM 2 Too much oil Damaged gaskets Replace seal Drain excess oil Refer to OPERATION Replace gaskets WINCH RUNS TOO SLOW Low flow rate Hydraulic motor worn out Check flow rate Refer to HYDRAULIC SYSTEMS performance chart page 2 Replace motor CABLE DRUM WILL NOT FREESPOOL Clutch not disengaged Check air pressure to clutch cylinder 100 PSI min required Refer to page 14 for port location BRAKE WLL NOT 1 RELEASE Brake line disconnected or blocked Check brake function Refer to page 12 LOAD LOWERS TOO FAST Hydraulic lines to counter balance valve incorrectly installed and or cartridge plug position incorrect for drum rotation direction to reel cable in Refer to View A A pg 14 for correct installation INSTRUCTIONS FOR OVERHAUL DIS ASSEMBLY
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