OPERATING, SERVICE AND MAINTENANCE MANUAL WILDCAT SERIES 80,000 LB INDUSTRIAL WINCH CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH.
TABLE OF CONTENTS WARRANTY INFORMATION ............................................................................................................... 1 SPECIFICATIONS ................................................................................................................................ 1 WARNINGS .......................................................................................................................................... 1 HYDRAULIC SYSTEM REQUIREMENTS .................................
RAMSEY HYDRAULIC PLANETARY WINCH MODEL WILDCAT 80K 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.
HYDRAULIC SYSTEM REQUIREMENTS Refer to the performance charts, below, to properly match your hydraulic system to winch performance. The charts consist of: (1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) line speed, first layer (FPM) vs. gallons per minute (GPM). Performance based on a motor displacement of 9.0 cubic inches/rev with 60 GPM maximum flow rate. Motor has (2) 1”-12 SAE straight thread o-ring ports.
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. Place taped end of cable into slot on drum flange and bend into track on drum flange. Secure using supplied u-bolt #62 and (2) nuts. 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. 4.
CLUTCH OPERATION WARNING: CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERATION. To engage clutch: 1. Move clutch control to engage the clutch. 2. Run the motor in the cable out direction until the drum begins to turn. WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD. To disengage clutch: 1. Run the winch in the "cable out" direction until the load is off the cable. 2. Move the clutch control to disengage the clutch. The cable may now be spooled off.
LUBRICATION TABLE Temp Range F(C) Lubricant Description* 80W140 Synthetic 75W90 Synthetic 80W90 Conventional 85W140 Conventional Min Ambient & Operating ‐25 (‐32) ‐40 (‐40) ‐20 (‐29) 20 (6) Max Max Operating Ambient 125 (52) 115 (46) 100 (38) 120 (50) 225 (107) 215 (102) 180 (82) 200 (93) *Use API GL‐5 or EP lubricants. 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 page 6.
INSTRUCTIONS FOR DISASSEMBLY 1. Remove wire rope from drum. 2. Drain oil from winch by removing (2) plugs #54, removing the lower plug first. 3. When replacing lubricant, use 264 oz of applicable lube for your climate form table on page 5, adding 4 oz at #44 and the remaining at # 55. 44 55 54 54 4. Remove (2) nuts #208b from air cylinder #208a. Air cylinder may now be removed.
5. Remove motor #45 from winch by first disconnecting hydraulic lines (see page 17), solenoid wires, and then remove (4) bolts #73. O-ring #72 may now be removed. 6. Remove brake cover #42 by removing (4) bolts #66. The cover is spring loaded, use care when removing. Remove o-ring #46 then springs #61 may be removed; residual oil may be present in the brake housing. 7.
9. Remove (8) cover bolts #36; cover #10, and o-ring #51. 10. Remove snap ring #58, and sun gear #17. 11. The planetary carrier assembly #4 may now be removed along with (2) spacers #24. 12. Remove second snap ring #58 and intermediate sun gear #16. 13. Planetary carrier assembly #3 may now be removed.
14. Using a nylon strap, support ring gear #20 from a hoist or boom, this ring gear is heavy. Remove (8) bolts #37 leaving the top most bolt for last. Remove the final bolt while supporting ring gear. Set ring gear aside. Remove the o-ring #52. 15. Remove spacer #26 and the output sun gear #15. 16. Using a large pair of snap ring pliers remove the snap ring #60 from the shaft located inside the planetary carrier assembly #2. 17.
19. Remove the clutch cylinder #1 by removing the (2) cotter keys #204 and (2) pins #206 from either end of the air cylinder #207. 20. The clutch cylinder support angle #8 can be removed by removing the four bolts #66 and nuts #65 attaching it to the mounting angles. 21. Remove the clutch yoke #29 by removing center pivot bolt #21 and nut #65.
22. By removing snap ring #58 and ball bearing #31, the input shaft #22 may be removed. 23. To remove the motor end bearing #18, support drum #14 with a nylon strap or chain and hoist. Lift on the drum to tension the strap. Remove (6) bolts #67 and (6) nuts #68 attaching the end bearing to the mounting angles #6 and #7. The motor end bearing #18 will be supported on the output shaft end and may be slid off using a nylon strap and hoist to lift it.
24. While continuing to support the drum #14, remove the clutch #9, snap ring #60 and spacer #25. 25. The output shaft #23 may be slid from the drum assembly. 26. The drum #14 is now supported only by the nylon strap and maybe removed as needed. 27. The (2) bushings #34 may be pressed from the drum if replacement is necessary.
28. To remove gear end bearing #18, from mounting angles #6 and #7, first remove (4) 7/8-9NC bolts #67 and (4) nuts #68 from each angle. Shaft oil seal #56 and end bearing bushing # 33 can be removed and replaced at this time, if necessary.
DISASSEMBLY OF CARRIER ASSEMBLY Carrier assemblies may be purchased as a complete assembly (see pg. 19) or parts may be purchased individually (see pg 16). If purchasing individual parts, it will be necessary to disassemble the gear carrier as outlined below. Disassembly/ assembly of carriers utilizes the same process for input carrier assembly #4, intermediate carrier assembly #3, and output carrier assembly #2. Detail shown below is for intermediate carrier assembly#3.
ASSEMBLY OF CARRIER ASSEMBLY 1. Place carrier #102 on flat clean surface. 2. A tool the width of the gear #105 and the diameter of the carrier pin #111 is helpful to install needle bearings #110. 3. Place the gear #105 on a flat thin clean metal plate; metal plate should not be thicker than thrust washer #115 and should be able to slide into gear pocket of carrier. Grease the inside of gear and insert the greased tool described above into gear. 4.
CARRIER ASSEMBLIES 112 105 112 115 110 115 112 115 108 106 110 110 115 110 109 110 104 115 115 102 INTERMEDIATE CARRIER* 107 Input Carrier* 111 114 107 OUTPUT CARRIER* 113 103 101 * Input Gear Assembly may be purchased under part number 296672 * Intermediate Gear Assembly may be purchased under part number 296671 * Output Gear Assembly may be purchased under part number 296670 Item 101 102 103 104 105 106 107 108 109 110 110 111 112 113 114 115 Qty 1 1 1 3 3 3 6 3 102 204 306 3 9 3
HOSE HOOKUP 21 21 41 69 41 32 53 41 69 21 30 32 20 41 17 OM-914207-0211-D
PARTS DRAWING 55 44 19 33 5 56 1 27 52 16 3 37 26 15 60 2 20 67 54 68 18 35 24 68 58 17 58 57 4 65 29 8 7 6 24 66 65 51 21 67 1 38 73 63 25 60 9 45 22 44 74 36 54 10 11 61 72 13 48 47 12 66 42 28 62 34 46 23 58 50 31 NOTES: 49 40 1. ITEM 1 - AIRCYLINDER KIT CONTAINS FASTENERS AND CYLINDERS FOR CLUTCH AND BAND BRAKE. 2. ITEM 63 CONTAINS FASTENERS FOR BRAKE VALVE. 3. HOSE KIT CONTAINS FITTINGS AND HOSE.
PARTS LIST ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 QTY 1 1 1 1 1 1 1 1 1 1 1 7 6 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 2 1 8 8 P ART NO 256131 296670 296671 296672 299748 303150 303151 312574 324510 328167 330016 330017 330018 332229 334198 334199 334200 338378 338380 338381 414543 357529 357530 362301 362302 362303 362304 362305 370062 432048 402132 432049 412119 412120 412121 414521 414658 DESCRIP TION AIR CYLINDER KIT OUTPUT CARRIER
AIR CYLINDER KIT #256131 PARTS LIST 204 201 204 202 202 206 203 209 205 204 206 203 208 207 ITEM 201 202 203 204 205 206 207 208 209 QTY 1 2 2 3 1 2 1 1 1 P AR T NO 408422 418067 418223 424005 424027 424205 433031 433032 448108 D ESCRIP TION MOUNTING BRACKET NUT-1/2-20NF HEX JAM WASHER-1/2 USS FLAT COTTER PIN- 1/8 DIA X 1 LG CLEVIS PIN-1/2 SHAFT DIA X 1 1/2 LG CLEVIS PIN-1/2 SHAFT DIA X 1 23/64 LG AIR CYLINDER AIR CYLINDER EYE BOLT 20 OM-914207-0211-D
DIMENSIONAL DRAWING GREASE ZERK LUBRICATE AS NOTED IN INSTRUCTION MANUAL SAE #16 O-RING PORT 1" LINE SIZE PAY-OUT PORT Bolt Size (inches) Thds Per Inch Bolt Torque (ft-lb) SAE Grade 5 12VDC SOLENOID CONNECT TO 2 SPEED SWITCH 50.61 1285,45 SAE Grade 8 7/16 14 54 78 1/2 13 78 119 5/8 11 154 230 3/4 10 257 380 7/8 9 382 600 1 8 587 700 49.47 1256,56 13.00 330,20 20.41 518,42 14.81 376,18 Ø21.00 533,40 10.21 259,21 25.25 641,36 Ø9.00 228,60 23.
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.
