Ramsey Electronics WILDCAT 80,000 LB Series, Operating, Service And Maintenance Manual

Page 1: ...OPERATING SERVICE AND MAINTENANCE MANUAL WILDCAT SERIES 80 000 LB INDUSTRIALWINCH CAUTION READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH SEE WARNINGS ...

Page 2: ...3 CLUTCH OPERATION 4 WINCH OPERATION 4 MAINTENANCE 4 LUBRICATION TABLE 5 TROUBLE SHOOTING GUIDE 5 INSTRUCTIONS FOR DISASSEMBLY 6 DISASSEMBLY OF CARRIER ASSEMBLY 14 ASSEMBLY OF CARRIER ASSEMBLY 15 CARRIER ASSEMBLIES 16 HOSE HOOKUP 17 PARTS DRAWING 18 PARTS LIST 19 AIR CYLINDER 20 DIMENSIONAL DRAWING 21 LIMITED WARRANTY 22 ...

Page 3: ...DIAMETER 1 INCH MAX FLOW 60 GPM LAYER OF CABLE CABLE CAPACITY LOW SPEED HIGH SPEED LINE PULL LINE SPEED LINE PULL LINE SPEED Ft m Lb Kg fpm mpm Lb Kg fpm mpm 1 50 20 80000 36280 30 9 30000 13630 60 18 2 115 45 66600 30200 36 11 25000 11350 72 22 3 185 73 57100 25900 42 13 21400 9730 84 26 4 270 106 50000 22670 48 15 18700 8520 96 29 5 365 144 44400 20130 54 16 16600 7560 108 33 These specification...

Page 4: ...e Motor has 2 1 12 SAE straight thread o ring ports Note A motor spool open center directional control valve is required for brake operation PORT 3 COUNTER BALANCE SPEED SELECTOR BLOCK BRAKE DIRECT LINE TO TANK PAYOUT COUNTER BALANCE VALVE RELIEF 4 WAY VALVE 3 POSITION SYSTEM PUMP CUSTOMER SUPPLIED MOTOR CASE DRAIN SAE 16 PORT 1 PORT 5 PAYIN MOTOR 2 SPEED 1 TUBING SIZE 1 TUBING SIZE SAE 16 LOW PRE...

Page 5: ...d 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 After installing cable band brake is used to prevent bird nesting while pulling out cable when clutch is disengaged 62 62 INSERT END OF CABLE INTO SLOT AS SHOWN B...

Page 6: ...icle 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 on the gear ho...

Page 7: ...worn out 1 Check flow rate Refer to HYDRAULIC SYSTEMS performance chart on page 2 2 Replace motor CABLE DRUM WILL NOT FREESPOOL 1 Clutch not disengaged 1 Check operation Refer to Clutch Operation on page 4 BRAKE WLL NOT HOLD 1 Incorrect directional control valve cylinder spool closed center 2 Excessive hydraulic system back pressure 3 Sprag clutch worn out 1 Use only a motor spool open center dire...

Page 8: ...page 5 adding 4 oz at 44 and the remaining at 55 55 54 54 44 4 Remove 2 nuts 208b from air cylinder 208a Air cylinder may now be removed If needed mounting bracket 201 may be removed by removing pin 204 from pin 205 and then sliding pin out of mounting bracket Brake band 5 may be expanded over drum flange to barrel for easiest removal NOTE BRAKE BAND FITS OVER DRUM FLANGE 5 14 201 208b 208a 205 20...

Page 9: ...brake housing 7 Remove piston 11 including o rings and backup rings 47 48 49 and 50 by using a momentary puff of compressed air into the brake port located on top of the end bearing Capture the piston by placing a shop rag over the opening prior to using air 8 Remove the sprag brake hub assembly 40 7 stator plates 12 6 disc brakes 13 and the spacer 28 The sprag brake hub assembly 40 is not a servi...

Page 10: ...p 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 4 36 10 51 24 24 3 16 58 17 58 8 OM 914207 0211 D ...

Page 11: ...r 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 Using a nylon strap and hoist slide the output planetary carrier 2 from the ring gear housing The output planetary carrier is heavy 18 Remove the spacer 27 20 37 26 15 60 2 27 52 9 OM 914207 0...

Page 12: ... 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 8 29 65 21 NOTE VIEW SHOWN LESS DRUM AND ANGLE CUT AWAY FOR CLARITY 65 29 1 CLUTCH YOKE 29 SHOWN REMOVED AND PARTIALLY INSTALLED FOR CLARITY 206 204 204 206 207 209 202 66 66 10 OM 914207 0211 D ...

Page 13: ...ith 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 67 68 18 22 31 58 7 14 67 6 11 OM 914207 0211 D ...

Page 14: ...0 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 14 34 23 25 60 9 34 12 OM 914207 0211 D ...

Page 15: ...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 67 18 67 68 68 33 56 7 6 13 OM 914207 0211 D ...

Page 16: ...embly 3 Please see page 16 for detailed parts list and drawings of individual carriers 1 Carefully drive roll pin 112 into carrier pin 111 so that it is captured within carrier pin 111 but not touching the opposite side of the intermediate carrier 102 2 Tap carrier pin 111 to remove it from the intermediate carrier 102 3 Place a plastic pail in a position to catch bearings 110 spacer 108 and washe...

Page 17: ...e next row of needle bearings 110 as detailed in step 4 above until all bearings are installed 6 With tool remaining in place slide the gear 105 resting on the thin plate into position in the carrier 102 7 Place thrust washer 115 on top of gear 105 Insert planet pin 111 into carrier 105 8 Turn carrier 102 on its side so that the gear is on top Remove the thin plate Remove tool by pushing planet pi...

Page 18: ...on 101 1 317018 Input Carrier 102 1 317019 Intermediate Carrier 103 1 317020 Output Carrier 104 3 334202 Output Planet Gear 105 3 334204 Intermediate Planet Gear 106 3 334206 Input Planet Gear 107 6 362306 Output Spacer 108 3 362307 Intermediate Spacer 109 102 402135 Input Needle Roller Bearing 110 204 402136 Intermediate Needle Roller Bearing 110 306 402136 Output Needle Roller Bearing 111 3 4701...

Page 19: ...17 OM 914207 0211 D HOSE HOOKUP 21 41 53 21 69 41 32 41 69 21 30 20 32 41 ...

Page 20: ... 25 60 9 22 21 57 29 1 8 35 18 7 66 67 38 73 63 45 44 61 11 47 48 13 12 28 58 31 40 49 50 46 42 66 72 NOTES 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 68 65 1 24 74 65 62 18 OM 914207 0211 D ...

Page 21: ...0 GEAR SUN 54 2 468041 PLUG 8 SAE 3 4 16 UNF 18 1 338378 END BEARING MOTOR SIDE 55 1 468042 REDUCER 3 4 16 SAE O RING X 1 8NPTF 19 1 338380 END BEARING GEAR SIDE 56 1 486087 SEAL OIL SHAFT SKF 42419 20 1 338381 HOUSING GEAR 57 1 486088 SEAL OIL SHAFT SKF 38653 21 1 414543 CAPSCREW 1 2 13NCX3LG HXHD GR 5 58 3 490006 SNAP RING 5100 125 22 1 357529 INPUT SHAFT 59 1 432054 FITTING JIC SWIVEL EL 23 1 3...

Page 22: ...1 408422 MOUNTING BRACKET 202 2 418067 NUT 1 2 20NF HEX JAM 203 2 418223 WASHER 1 2 USS FLAT 204 3 424005 COTTER PIN 1 8 DIA X 1 LG 205 1 424027 CLEVIS PIN 1 2 SHAFT DIA X 1 1 2 LG 206 2 424205 CLEVIS PIN 1 2 SHAFT DIA X 1 23 64 LG 207 1 433031 AIR CYLINDER 208 1 433032 AIR CYLINDER 209 1 448108 EYE BOLT 20 OM 914207 0211 D ...

Page 23: ...VDC SOLENOID CONNECT TO 2 SPEED SWITCH SAE 16 O RING PORT 1 LINE SIZE PAY OUT PORT Ø21 00 533 40 DRUM C L GREASE ZERK LUBRICATE AS NOTED IN INSTRUCTION MANUAL Bolt Size inches Thds Per Inch SAE Grade 5 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 Bolt Torque ft lb 23 93 607 90 25 25 641 36 8 00 203 20 4 00 101 60 20 00 508 00 Ø9 00 228 60 10 21 25...

Page 24: ...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 de...