Ramsey Winch CABLE TENSIONER AIR ACTUATED RPH 35000 256126 - Manual

INSTALLATION INSTRUCTIONS FOR
AIR ACTUATED CABLE TENSIONER KIT #256126
This Tensioner Kit is designed specifically for Ramsey Winch Model RPH 15,000 Series Winches. The Tensioner
requires an independent, adjustable regulated air supply of between 50 psi and 90 psi. If you do not provide an
adjustable air supply you will not be able to adjust the effort of the free-spool. If your vehicle is not equipped with an
independent, adjustable air pressure regulator (used only for the tensioner) or you are unable to adjust it to a setting in
the range indicated, order pressure regulator kit #256092 from Ramsey.
INSTALLATION PROCEDURE
Disengage the winch clutch and free spool all the cable except for the last wrap off the winch. Lay cable out in a
straight line behind the truck to prevent kinking. Loosen capscrews holding tie bar and remove tie bar. Attach mounting
angle (item #2) provided with tensioner kit to winch with existing capscrews. Tighten capscrews to 173 ft-lbs. (235 Nm).
Attach the tensioner bracket assembly (item #6) to the mounting angle using (2) 1/2-13NC x 1-1/2 capscrews, nuts, and
washers (items #9, #10, and #12). Attach loosely, do not tighten. Assemble the tensioner kit as shown on the next page.
Do not over-tighten capscrews and nuts going into the actuators (items #7 and 11) or fittings (items #14 and #15).
Attach the tensioner bar (item #3) to the pivot plate (item #1) and tighten to 23 ft-lbs. (31 Nm).
Center the tensioner bar between the drum flanges with a scale or tape measure by moving the entire assembly on the
mounting angle. Be sure to keep the tensioner bar parallel to the drum barrel. Tighten the 1/2” capscrews to 60 ft-lbs.
(81 Nm).
If you removed the cable entirely from the winch or this is a new installation: The cable tensioner is not intended
to be energized on a bare drum. Before applying air to the cable tensioner, engage the clutch and run the winch in the
reel in direction winding one full wrap of cable on the drum. This prevents damage to the cable tensioner.
Attach the regulated air supply to the “T” fitting on the tension-
er (see figure at right). Hand tighten the nut. Do NOT tighten
more than 1/4 turn beyond hand tight. Apply air to the ten-
sioner. Engage the clutch and run the winch in the reel in direc-
tion winding about five wraps of cable onto the drum and stop.
Using a hammer tap these five wraps tightly over against the
cable anchor flange side of the cable drum. Finish winding all
the cable onto the cable drum. As cable winds onto the drum,
watch the tensioner. Tensioner must be free to move without
obstruction to function properly. If tensioner touches any sur-
rounding structure, correct the problem.
Adjust the free-spool effort of the cable tensioner. Disengage the
winch clutch and free spool some cable off the drum. Adjust the
air pressure to the cable tensioner to achieve the desired free
spool effort that also prevents "bird nesting" of the cable.
CAUTION: DO NOT EXCEED 100 PSI AIR PRESSURE TO THE ACTUATORS.
OPERATION
Once you have adjusted the air pressure to the desired level, only minor adjustment may be required if your pressure
regulator setting drifts.
RAMSEY WINCH COMPANY
P.O. BOX 581510
TULSA, OKLAHOMA 74158
KI-913399-0305-A
TENSIONER BAR
DO NOT TIGHTEN FITTING NUTS MORE
THAN 1/4 TURN BEYOND HAND TIGHT
FITTING NUT