Ramsey Winch RPH 133,4 Installations- und Benutzerhandbuch

English (Original Instructions) . . . . . . . . . . . . . . . 1

Français (Traduction des instructions originales) . . 19

Deutsch (Übersetzung der Originalanleitung) . . . . . 38

Español(Traducción de las instrucciones originales) 56

MODEL RPH 133,4

INDUSTRIAL

PLANETARY WINCH

Intended Purpose: Vehicle recovery and pulling of loads

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND

OPERATION OF WINCH. SEE WARNINGS!

OPERATING, SERVICE AND

MAINTENANCE MANUAL

Ramsey Authorized Representative in the Community:

(Please contact for regulatory inquiries only. )

Alura Group BV

P.O. Box 18626

2502 EP The Hague

The Netherlands

Tel: (31) (0) 70 362-4896

Fax: (31) (0) 70 346-7299 OM-914217-0611-A

RAMSEY WINCH COMPANY

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

Phone: (918) 438-2760 Fax: (918) 438-6688

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

4707 N. Mingo Tulsa, Oklahoma 74117 (918) 438-2760

EC DECLARATION OF CONFORMITY

as defined by Machinery Directive 2006/42/EC

Here with we declare that winch model RPH 133,4 com-

plies with the following directive provided that the USER

complies with all responsibilities described in the Owner’s

Manual:

2006/42/EC

Applied harmonized standards:

EN 14492-1:2006

Power-Driven Winches

ISO 9001:2000

Quality Management Systems

Requirements

DÉCLARATION DE CONFORMITÉ EC

aux termes de la directive Machines 2006/42/EC

Nous déclarons par la présente que le modèle de treuil

RPH 133,4 est conforme à la directive suivante, sous

réserve que l’UTILISATEUR ait assumé toutes les respons-

abilités figurant dans le manuel de l’utilisateur :

2006/42/EC

Normes harmonisées appliquées :

EN 14492-1:2006

Treuils motorisés

ISO 9001:2000

Systèmes de gestion de la qualité - Exigences

EC-KONFORMITÄTSERKLÄRUNG

gemäß Maschinenrichtlinie 2006/42/EC

Hiermit erklären wir, dass das Windenmodell

RPH 133,4 der folgenden Richtlinie entspricht, sofern

der BENUTZER alle Anweisungen im Benutzerhandbuch

befolgt:

2006/42/EC

Angewandte harmonisierte Normen:

EN 14492-1:2006

Kraftgetriebene Winden

ISO 9001:2000 Qualitätsmanagementsysteme -

Anforderungen

DECLARACIÓN EC DE CONFORMIDAD

según se define en la directiva de máquinas 2006/42/EC

Con la presente declaramos que el modelo de cabestrante

RPH 133,4 se halla en conformidad con la siguiente directiva

siempre que el USUARIO cumpla todas las responsabili-

dades descritas en el Manual del propietario:

2006/42/EC

Normas armonizadas aplicadas:

EN 14492-1:2006

Cabestrantes accionados mecánicamente

ISO 9001:2000

Requisitos de los Sistema de gestión de la calidad

Ramsey Authorized Representative in the Community / Ramsey Représentant autorisé dans la comuauté /

Ramsey Bevollmächtigter in der Europäischen Union / Ramsey Representante autorizado en la comunidad.

(Please contact for regulatory inquiries only. / Veuillez prendre contact uniquement pour des questions réglementaires.)

(Bitte nur bei Regulierungsfragen kontaktieren. / Póngase en contacto sólo por cuestiones de reglamentación.)

Alura Group BV

P.O. Box 18626

2502 EP The Hague

The Netherlands

Tel: (31) (0) 70 362-4896

Fax: (31) (0) 70 346-7299

Serial Number / Numéro de série/ Seriennummer/ Número de Serie:_____________________

Signature / Signature / Unterschrift / Firma:

Todd Brady

Engineering Manager / Directeur technique/ Technischer Leiter/ Director de ingeniería

Date / Date / Datum / Fecha:

06-13-11

TABLE OF CONTENTS

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

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

USER’S RESPONSIBILITY FOR CE COMPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

WINCH FRAME MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

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

END OF SERVICE MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

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

MOUNTING CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14

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

ROPE TENSIONER OVERHAUL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

ROPE TENSIONER PARTS LIST AND PARTS DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . .18

CE DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

SPECIFICATIONS*

WARNINGS:

THE USER SHALL ENSURE THAT THE OPERATING PERSONNEL ARE GIVEN THE NECESSARY TRAINING.

THE OPERATOR SHALL ALWAYS WORK IN COMPLIANCE WITH THE OPERATING INSTRUCTIONS.

A MOTOR SPOOL (OPEN CENTER) DIRECTIONAL CONTROL VALVE IS REQUIRED FOR BRAKE OPERATION.

CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCH.

DO NOT DISENGAGE CLUTCH UNDER LOAD.

STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS.

STAND CLEAR OF ROPE WHILE PULLING. DO NOT TRY TO GUIDE ROPE.

DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PERSONNEL.

A MINIMUM OF 2 WRAPS OF ROPE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.

AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR. EXCESSIVE “INCHING” SHALL BE AVOIDED.

USER’S RESPONSIBILITY FOR CE COMPLIANCE

1. Use only a motor spool (open center) control valve Per Hydraulic System Requirements.

2. If a remote-operated winch control valve is used, refer to Hydraulic System Requirements for

Emergency Stop components to be installed.

3. Adjust system relief pressure per Hydraulic System Requirements

4. Mount winch per Winch Mounting Instructions.

5. Install 20 mm (.787 inch), grade 1960 wire rope. Maximum rope length of 62 M (205 ft) for

four layers maximum. Attach rope to the drum per Rope Installation Instructions. Hook must

have a safety latch and a minimum breaking strength of 334 kN.

First Layer Line Pull 133,4 kN (30000 lb)

Noise Level 76 db

Ambient Temperature Range -28C to 60C (-20F to 140F)

Gear Reduction 31:89:1

Weight (without rope) 261 kg (575 lb)

LAYER OF ROPE 1 2 3 4

Line pull per layer kN 133,4 111,2 95,3 83,3

lb 30,000 24,900 21,400 18,700

* Rope Capacity per Layer m102542 62

ft 35 85 140 205

* Line Speed at 56,7 LPM (15

GPM)

MPM 5,5 6,3 7,2 8,5

FPM 18 21 24 28

* These specifications are based on recommended 20 mm (.787") 1960 grade wire rope and a 195 cc (11.9 cu in /Rev)

motor.

1,5 (5)

4,6 (15)

44,5 (10,000)

66,7 (15,000)

89,0 (20,000)

111,2 (25,000)

0 137,9 206,8

68,9

(0) (2000) (3000)

(1000)

133,4 (30,000)

0 18,9 37,9 56,7

(0) (5) (10) (15)

3,1 (10)

6,1 (20)

WORKING PRESSURE bar (PSI) AT 56,7 LPM (15 GPM)

LINE PULL-FIRST LAYER kN (lb)

LINE SPEED-FIRST LAYER MPM (FPM)

FLOW LPM (GPM)

PERFORMANCE CHARTS

BASED ON 195 cc (11.9 cu in) MOTOR

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 kN (lb) vs. Working Pressure bar (PSI). (2) Line Speed, first layer MPM

(FPM) vs. flow LPM (GPM).

HYDRAULIC SYSTEM REQUIREMENTS

1. Motor spool (open center) control valve

2. Emergency Stop:

A. If winch is controlled by a direct-operated manual valve, that valve serves as the E-stop.

B. If a remote operated control valve is used, a solenoid-operated hydraulic dump valve, normally open to

tank, and an emergency stop switch (to open the dump valve) is required. The E-stop switch is to be

normally closed and have a red, resettable push button actuator with a yellow background. The E-stop

switch must be easily accessible to the operator.

3. Relief valve set to 207 bar (3000 psi) which is the rated capacity limiter.

4. Flow rate of 56,7 LPM (15 GPM) maximum. Do not exceed 75,7 LPM (20 GPM) or motor and winch may be

damaged.

5. Hydraulic fluid with a viscosity between 20-43 cSt (100-200 SUS). Maximum operating temperature 85C

(180F). Cleanliness level of ISO 17-14 or better.

(RATED CAPACITY LIMITER)

56,7 LPM (15 GPM)

19 mm (.75 in) I.D. MINIMUM

I.D. MINIMUM

12,7 mm (.50 in)

TYPICAL LAYOUT

PUMP

LOW PRESSURE LINE

HIGH PRESSURE LINE

RATED LOAD:

PRESSURE AT

MAX. FLOW &

(MOTOR SPOOL)

4 WAY VALVE

3 POSITION

SYSTEM RELIEF

PORT

BRAKE

MOTOR

WITH BRAKE RELEASE SHUTTLE

DUAL-A & B PORT CONTROL

PROVIDED BY USER

DUMP VALVE

*E-STOP SWITCH

REQUIRED ONLY IF REMOTE-OPERATED CONTROL VALVE IS USED. SEE 2B

*IN HYDRAULIC SYSTEMS REQUIREMENTS. NOT REQUIRED FOR A

DIRECT-OPERATED MANUAL VALVE.

207 BAR (3000 PSI)

207 bar (3000 PSI)

WINCH FRAME MOUNTING

Use (8) 5/8 inch diameter grade 5 or better bolts to attach mounting frame to wrecker.

ROPE INSTALLATION

The RPH 133,4 winch has two tapered pockets cast into the drum. One pocket is for installations with the

wire rope wound over the drum. The other pocket is for an underwound wire rope.

1. Unwind rope by rolling it out along the ground to prevent kinking. Securely wrap end of wire rope, oppo-

site hook, with plastic or similar tape to prevent fraying.

2. Slide the wire rope through narrow end of the pocket against the drum flange and wrap the wire rope

around the anchor "puck" and pull the wire rope and anchor back into the wide end of the pocket. Use a

soft hammer to drive the back side of the wire rope, firmly seating the wire rope and anchor, into the

pocket.

3. Carefully run winch in the "reel-in" direction. Keeping tension on end of rope, spool all the rope onto the

rope drum, taking care to form neatly wrapped layers.

CLUTCH OPERATION

To engage clutch:

1. Move the clutch control valve to the "clutch-engaged" position.

2. Anytime the temperature is below freezing, run motor in the "rope out" direction only until the drum starts

to turn.

2a. In extreme cold temperatures (below -18oC/ 0oF), pull out on the rope 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 rope.

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 "rope out" direction until the load is off the rope.

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

3. The rope 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 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. Gain confidence in

operating your winch and its use will become second nature with you.

The uneven spooling of rope, while pulling a load, is not a problem, unless there is a rope pileup on one end

of drum. If this happens reverse the winch to relieve the load and move your anchor point further to the cen-

ter of the vehicle. After the job is done you can unspool and rewind for a neat lay of the rope.

INSERT ROPE AS SHOWN FOR

UNDERWOUND APPLICATION

INSERT ROPE AS SHOWN FOR

OVERWOUND APPLICATION

ROTATION

DIRECTION

TO REEL IN

ROTATION

DIRECTION

TO REEL IN

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 rope 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 rope. If the rope has become frayed with broken strands, replace immediately.

C. ANNUALLY

1. Drain the oil from the winch annually or more often if winch is used frequently.

2. Fill the winch to the oil level plug with clean kerosene. Run the winch a few seconds with no load in the

reel in direction. Drain the kerosene from the winch.

3. Refill the winch to the oil level plug with all purpose SAE 80W-140 gear oil.

4. Inspect frame and surrounding structure for cracks or deformation.

END OF SERVICE MEASURES

When winch reaches the end of it’s servicable life, dispose of per local environmental regulations.

TROUBLE SHOOTING 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 gasket. 3. Replace gasket.

--------------------------------------------------------------------------------------------------------------------------------------

WINCH RUNS TOO SLOW 1. Low flow rate 1. Check flow rate.Refer to flow

HYDRAULIC SYSTEMS flow chart page 2.

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

--------------------------------------------------------------------------------------------------------------------------------------

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

FREESPOOL cylinder 6,2 bar (90 PSI) mini

mum required-Refer to page

2. If equipped with air 2. Reduce air pressure to

tensioner, too much tensioner actuators.

force on tensioner bar.

-------------------------------------------------------------------------------------------------------------------------------------

BRAKE WILL NOT RELEASE 1. Air in hydraulic system 1. Bleed air from brake. Refer

to page 2.

INSTRUCTIONS FOR OVERHAUL

1. Drain oil from gear housing item #11 by removing plug item #47 from end bearing. Remove reducer and relief fitting

items #41 & #46.

If new air cylinder is required, remove air cylinder item #37 from adapter item #4 by removing (4) capscrews item #26.

Remove breather vent item #42. Remove washer item #30, nut and setscrew items #31 & #25 and insert item #34

from end of air cylinder rod. Apply Loc-tite to threads of nut item #31 and thread onto setscrew item #25 to 10 mm (3/8

inch) from drive end, as shown below. Apply Loc-tite to threads of setscrew and thread insert item #34 over end of

setscrew and against nut. Use setscrew and nut to thread insert item #34 into end of air cylinder rod. Tighten nut

against cylinder rod, keeping 10 mm (3/8 inch) distance from drive end of setscrew to nut. Be sure breather vent item

#42, and relief fitting item #41are not damaged and in good operating condition. Remove and replace if necessary.

Remove air cylinder adapter item #4 and gasket item #40 from gear housing cover by unscrewing (4) capscrews item

#21.

2. Disconnect tube item #50 from elbow item #35 and fitting item #36 on bottom of brake item #38. Remove motor item

#43 and gasket item #38b by removing (2) capscrews item #24. Remove valve item #51, if needed, from motor by

loosening (3) capscrews item #22 (not shown).

(3/8)

APPLY LOC-TITE TO SETSCREW

AIR CYLINDER

ROD

25 34

10 mm

38b

38a

3. Remove brake assembly screws item #18 from brake #38a to access (2) mounting screws item

#23 attaching brake adapter plate #38d to end bearing item #10. CAUTION: Brake is spring

loaded by clutch spring and must be restrained against end bearing as mounting screws

item #23 are removed. Remove coupling item #8 and gasket item #38e from end bearing. Take

note of mounting configuration for proper mounting of parts during re-assembly.

4. Remove winch from upright mounting frame item #2 by removing (8) capscrews item #20, (8) lockwashers item #29

and (4) shoulder bolts item #32. Pull motor end bearing item #10 from drum assembly item #1.

38e

38d

38e

38a

38c

20 29

5. Pull drum assembly item #1 upward from end bearing item #11. Remove quad-rings item #44 &

#45 from grooves in drum bushings. Remove input shaft item #13, clutch spring item #49 and

washer item #33 from end bearing item #11. Examine key item #12 and input shaft for signs of

wear, replace if damaged.

Examine drum assembly item #1 for signs of wear. If splines inside of drum driver #1g are dam-

aged, it must be replaced. Remove drum driver #1g by unscrewing (8) capscrews #1f. Place well

oiled o-ring #1d into drum driver groove and attach driver to drum #1c using (8) capscrews #1f.

Torque capscrews #1f to 163 Nm (120 ft lb) each, in criss-cross pattern.

Press old bushings #1a and #1j from drum #1c and drum driver #1g. Remove o-rings #1b and 1h

from grooves in drum #1c and drum driver bushing #1j. Place well oiled o-rings #1b and #1h into

grooves in drum #1c and outer diameter of drum driver bushing #1j. Press new bushing #1a into

end of drum #1c opposite drum driver #1g and press bushing #1j into drum driver #1g until flange

of bushings are flush against drum #1c and driver #1g.

DRUM ASSEMBLY

49 33

1g 1j

GROOVE

DRUM DRIVER

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