Ramsey Winch HD-P50000 Installations- und Benutzerhandbuch
OM 914244-0414-G
OPERATING, SERVICE AND
MAINTENANCE MANUAL
MODEL HD-P50,000
INDUSTRIAL PLANETARY WINCH
WITH AIR TENSIONER AND 2 SPEED MOTOR
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND
OPERATION OF WINCH. SEE WARNINGS!
TABLE OF CONTENTS
INTRODUCTION
………………………………
1
WARRANTY INFORMATION
………………………………
1
SPECIFICATIONS
………………………………
1
WARNINGS
………………………………
1
HYDRAULIC SYSTEM REQUIRE
ME
…………………………
……
2
PERFORMANCE CHARTS …………………………
……
2
WINCH OPERATION …………………………
……
3
CLUTCH OPERATION …………………………
……
3
CABLE INSTALLATION …………………………
……
3
MAINTENANCE
………………………………
4
TROUBLE SHOOTING GUIDE
………………………………
4
INSTRUCTIONS FOR OVERHAUL
………………………………
5-9
MOUNTING CONFIGURATIONS
………………………………
10
DIMENSIONAL DRAWING
………………………………
11
PARTS LIST AND PART DRAWING
………………………………
13-16
LIMITED WARRANTY
………………………………
Last Page
1
PLEASE READ THIS MANUAL CAREFULLY
This manual contains useful ideas in obtaining the most efficient operation from your Ramsey Winch, and safety
procedures one needs to know before operating a Ramsey Winch. Do not operate this winch until you have
carefully read and understand the “WARNINGS” and “OPERATION” sections of this manual.
WARRANTY INFORMATION
Ramsey Winches are designed and built to exacting specifications. Great care and skill go into every winch
we make. If the need should arise, warranty procedure is outlined on the back of your self-addressed postage
paid warranty card. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company.
If you have any problems with our winch, please follow instructions for prompt service on all warranty claims.
Refer to back page for limited warranty.
SPECIFICATIONS* (LOW SPEED MODE)
WARNINGS:
CLUTCH MUST BE TOTALLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.
DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS.
STAND CLEAR OF CABLE WHILE PULLING. DO NOT TRY TO GUIDE CABLE.
DO NOT EXCEED MAXIMUM LINE PULL RATINGS SHOWN IN TABLE.
DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PEOPLE.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.
CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD.
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire
rope ratings.
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2
HYDRAULIC SYSTEM REQUIREMENTS
Refer to the performance charts to properly match your hydraulic system to HDP-50000 winch performance.
The charts consist of:
(1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) Line speed (FPM) first layer vs. flow (GPM).
Performance is based on a motor displacement of 11.9 cubic inches with 25 GPM maximum flow rate. See
page 10 for motor port size.
B
TYPICAL LAYOUT
WITH BRAKE RELEASE SHUTTLE
MOTOR
BRAKE
PORT
A
SYSTEM
RELIEF
3 POSITION
4 WAY VALVE
(MOTOR SPOOL)
MAX. FLOW &
PRESSURE AT
RATED LOAD:
HIGH PRESSURE LINE
(.50 I.D. MINIMUM) LOW PRESSURE LINE
(.75 I.D. MINIMUM)
PORT CONTROL
25 GPM
3000 PSI
PERFORMANCE CHARTS
(BASED ON 11.9 CU. IN./REV MOTOR)
40000
45000
50000
45
40
25
PERFORMANCE WITH 11.9/5.95 IN 2-SPEED HYDRAULIC MOTOR:
3
HIGH SPEED
LOW SPEED
30
35
FIRST LAYER
FLOW (GPM)
2015105
0
25
20
15
10
5
0
LINE SPEED (Ft/Min.)
25000
3000
20000
10000
15000
2500200015001000500
PRESSURE (PSI)
FIRST LAYER
LINE PULL (Lbs.)
30000
35000
0
5000
HYDRAULIC SYSTEM REQUIREMENTS
HYDRAULIC SYSTEM REQUIREMENTS
3
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 recog-
nize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Gain
confidence in operating your winch and its use will become second nature with you.
The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pileup on
one end of drum. If this happens, reverse the winch to relieve the load and move your anchor point
further to the center of the vehicle. After the job is done you can unspool and rewind for a neat lay of
the cable.
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 0˚ F/-18˚ 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 mo-
tor is running. Do not start picking up the load at the same time the clutch is being
engaged.
To disengage clutch:
1. Run the winch in the “cable out” direction until the load is off the cable.
2. Move the clutch control valve to the “clutch-disengaged” position.
3. The cable may now be pulled off by hand.
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.
WINCH OPERATION
4
MAINTENANCE
Adhering to the following maintenance schedule will keep your winch in top condition and per-
forming 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 the gear housing cover. Be sure that it is not plugged.
3. Lubricate cable with light oil.
B. MONTHLY
1. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that
are loose. Use grade 5 or better bolts.
2. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.
C. ANNUALLY
1. Drain the oil from the winch annually or more often if winch is used frequently.
2. Fill the winch to the oil level plug with clean kerosene. Run the winch a few seconds with no load
in the reel in direction. Drain the kerosene from the winch.
3. Refill the winch to the oil level plug with all-purpose SAE 75W-90 synthetic gear oil.
4. Inspect frame and surrounding structure for cracks or deformation.
TROUBLESHOOTING GUIDE
CONDITIONS POSSIBLE CAUSE CORRECTION
OIL LEAKS FROM
WINCH
1. Seals damaged or
worn.
1. Replace seal.
2. Too much oil. 2. Drain excess oil. Refer to OPERATION.
3. Damaged gaskets. 3. Replace gaskets.
WINCH RUNS
TOO SLOW
1. Low flow rate 1. Check flow rate. Refer to HYDRAULIC SYS-
TEMS performance chart page 2.
2. Hydraulic motor
worn out.
2. Replace motor.
CABLE DRUM
WILL NOT FREE-
SPOOL
1. Clutch not disen-
gaged
1. Check air pressure to clutch cylinder: 100 PSI
Minimum required. Refer to page 10 for port
location.
BRAKE WLL NOT
RELEASE
1. Brake line discon-
nected or blocked.
1. Check brake function.
MAINTENANCE
5
2. Disconnect tube #40 from elbow #43 on valve #41 and fitting #29 on brake #30b. Remove motor #33 and
gasket #30a by removing (2) capscrews #22. Remove valve #41, if needed, from motor by loosening (4)
capscrews #16.
30a
33
41
40
16
22
43
DIS-ASSEMBLY
1. Drain oil from gear housing cover by removing pipe plug #37 and relief fitting #32. Remove tensioner
assembly.
INSTRUCTIONS FOR OVERHAUL
6
31
42
15
31
5
18
3. Remove (12) capscrews #18 to remove gear housing cover and gasket from ring gear. Remove
input thrust washer, sun gear and input carrier assembly from inside ring gear. Remove ring gear
and gasket. Remove output carrier assembly. Inspect gear housing cover bushing #15 for damage
or wear. Replace if damaged or excessive wear.
4. Remove (8) capscrews #20 to remove clutch retainer plate #10 from clutch piston. Remove
clutch #9.
9
10
20
7
5. Remove clutch housing #27 with piston #28 inside. To remove piston from clutch housing apply air to 1/8”
port. Remove o-rings #28 and #35 and inspect for damage or wear.
36
28
35
27
6. Remove (9) springs #39, thrust washer #26, gasket #31, output shaft #12 and spacer #13 from gear end
bearing. Inspect output shaft bushing #14 for damage or wear. Replace if damaged or excessive wear.
13
12
26
14
31
39
8
7. Remove winch tie bars #2 and #3 by removing (8) capscrews #19, (8) lock washers # 24, and (4)
shoulder bolts #25. Pull gear end bearing #7 from drum assembly #1.
24
24
19
19
25
25
2
7
24
24
19
25
25
19
3
38
6
8
11
34
23
1
34
4
8. Pull drum assembly #1 from end bearing #6. Remove quad-rings #34 from grooves in drum bush-
ings. Remove input shaft #11 from end bearing. Examine splined ends of input shaft for signs of wear,
replace if damaged. Examine drum assembly #1 for signs of wear.
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