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OPERATING, SERVICE ANDMAINTENANCE MANUAL
MODEL RPH 15,000 PLANETARY WINCH
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION ANDOPERATION OF WINCH. SEE SAFEGUARDS AND WARNINGS!
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HYDRAULIC SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MANUAL CLUTCH SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
AIR CYLINDER CLUTCH SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
INSTRUCTIONS FOR OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13
DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
PARTS LIST AND PARTS DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-19
LIMITIED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BACK COVER
RAMSEY HYDRAULIC PLANETARY WINCH MODEL RPH 15,000PLEASE READ THIS MANUAL CAREFULLYThis manual contains useful ideas for obtaining the most efficient operation from your Ramsey Winch, and safety procedures one needs toknow before operating a Ramsey Winch. Do not operate this winch until you have carefully read and understand the "WARNING" and"OPERATION" sections of this manual.
WARRANTY INFORMATIONRamsey Winches are designed and built to exacting specifications. Great care and skill go into every winch we make. If the need shouldarise, warranty procedure is outlined on the back of your self-addressed postage paid warranty card. Please read and fill out the enclosedwarranty card and send it to Ramsey Winch Company. If you have any problems with your winch, please follow instructions for promptservice on all warranty claims. Refer to back page for limited warranty.
SPECIFICATIONS*
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.
WARNINGS:
CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCH.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
DO NOT LEAVE CLUTCH ENGAGED WHEN WINCH IS NOT IN USE.
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 PERSONNEL.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD. CABLE CLAMP(SETSCREW) IS NOT DESIGNED TO HOLD LOAD.
IN CAR CARRIER APPLICATIONS, AFTER PULLING VEHICLE ON CARRIER, BE SURE TO SECURE VEHICLE TO CARRIER BED. DONOT MAINTAIN LOAD ON WINCH CABLE WHILE TRANSPORTING VEHICLE. DO NOT USE WINCH AS A TIE DOWN.
WHEN PULLING A HEAVY LOAD PLACE A BLANKET, JACKET, OR TARPAULIN OVER THE CABLE FIVE OR SIX FEET FROM THE HOOK.
AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR, AS THEY MAY INDICATE A DANGEROUS SITUATION.
3
(Short Drum)
(Standard Drum)
60
195
45
150
33
110
22
75206
Ft.M.
Cable capacity 45
13
94
310
14,648
54
180
11,839
38
125
10,334
13,444
73
240
3,440
7,600
3,850
8,500
4,300
9,500
4,890
10,800Lbs.*Rated line pull
3510
7,625
M.Ft.
FPMMPM
Cable capacity
Line speed(at 15 GPM)
6,800
15,000Kg.per layer
8,829
5,710
12,600
22
75
**Last layer does not comply with SAE J-706
rope and a 24.0 Cu. In./Rev. motor.
LAYER OF CABLE 1 2 3 4 5 6**
Gear Reduction............................................................................................................7.7:1
Weight, Std. Drum (without cable)..........................................................300 lbs. (136 kgs.)
(kgs.).................................................................................................. 6,800
Rated Line Pull (lbs.)..................................................................................................15,000
*These specifications are based on recommended 1/2" (13 mm) EIPS wire
Weight, Short Drum (without cable)........................................................290 lbs. (131 kgs.)
WINCH MOUNTING
ESSENTIAL MOUNTING INSTRUCTIONS TO MAINTAIN ALIGNMENT OF PLANETARY WINCH COMPONENTS
It is most important that this winch be mounted securely so that the three major sections (the motor end, thecable drum and the gear housing end) are properly aligned. Excessive bushing wear and difficulty in freespoolingare usually symptoms of misalignment.
In the as-installed condition, if the winch is mid mounted at least one tie plate must be attached to the mounting feetat the bottom of the winch to maintain alignment. NOTE: If the winch is foot mounted at least one tie plate mustremain mounted at mid point of winch to maintain alignment. It is always desirable to use both tie plates in the finalinstalled configuration.
Angle Mounting Kit, #251173, is recommended for maximum ease in mounting the winch. The angle kit will allowthe winch to be mounted in upright or midmount applications and will meet the criteria of serving as a solid and truemounting surface.
When mounting the winch with other than the recommended Ramsey Angle Kit, the mounting hole patternsdescribed on pages 14-15 must be used. The mounting surface must be flat within .015 inch and sufficiently stiff toresist flexing. If a steel plate is used for foot mounting it should be .750 inch thick. For this mounting applicationeight (8) 5/8-11NC x 1-1/2 Lg. Gr. 5 capscrews with lockwashers will be needed to mount winch. Capscrewsshould be torqued to 173 ft. lb. (235 Nm.).
NOTE: If angles or a steel plate are used in mounting winch, tie plates provided with winch are to be attached to theremaining mounting pads, whether they be side or foot.
4
CABLE INSTALLATION
1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of cable, opposite hook,with plastic or similar tape to prevent fraying.
2. Place taped end of cable into hole in cable drum, as shown below. Use 3/8-16NC x 1/2 lg. Hx. Soc. drivesetscrew (part of 234173 drum assembly) to secure cable to drum.
3. Carefully run winch in the "reel-in" direction. Keeping tension on end of cable, spool all the cable onto the cabledrum, taking care to form neatly wrapped layers.
After installing cable, check freespool operation. Disengage clutch and pull on cable at a walking speed. If cable"Birdnests", loosen jam nut (item #22) and turn nylon screw (item #19) clockwise to increase drag on drum. Ifcable pull is excessive loosen nylon setscrew by turning counterclockwise. Tighten jam nut when proper setting isobtained. CAUTION: OVER-TIGHTENING OF JAM NUT MAY STRIP NYLON SETSCREW.
5
HYDRAULIC SYSTEM REQUIREMENTS
Refer to the performance charts below to properly match your hydraulic system to the winch performance. Thecharts consist of: (1) line pull (LB) first layer vs. working pressure (PSI); (2) line speed, first layer (FPM) vs. flow(GPM). A motor spool directional control valve is recommended.
* Caution: Do not exceed 20 G.P.M. If exceeded, motor and winch may be damaged.
PERFORMANCE CHARTS
SYSTEM REQUIREMENTS:
2500 PSI RELIEF VALVE SETTING
15 G.P.M. FLOW RATE *
10 MICRON NORMAL FILTRATION
6
HIGH PRESSURE LINE
(.50 I.D. MINIMUM)
CONTROL VALVE
3 POSITION
4 WAY VALVE(MOTOR SPOOL)
DUAL-A & B PORT CONTROL
WITH BRAKE RELEASE SHUTTLE
BRAKE
PORT
B
MOTOR
A
TYPICAL LAYOUT
LOW PRESSURE LINE
(.75 I.D. MINIMUM)
MAX. FLOW &
PRESSURE AT
RATED LOAD:
15 GPM
2500 PSI
PUMP
PERFORMANCE WITH 24.0 CU. IN. HYDRAULIC MOTOR:
LIN
E P
ULL, LB
S
FIR
ST
LA
YE
R
FIR
ST
LA
YE
R
LIN
E S
PE
ED
, F
PM
WORKING PRESSURE, PSIAT 15 GPM
50000
250020001000 1500
3000
6000
FLOW, GPM
00
155 10
5
10
15000
9000
12000
25
15
20
OPERATION
The best way to get acquainted with how your winch operates is to make test runs before you actually use it. Planyour test in advance. Remember, you hear your winch, as well as see it operate. Get to recognize the sounds of alight steady pull, a heavy pull, and sounds caused by load jerking or shifting. Avoid conditions where load shifts orjerks occur, as they may indicate a dangerous situation.
The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pileup on one end ofdrum. If this happens, reverse the winch to relieve the load and move your anchor point further to the center of thevehicle. After the job is done you can unspool and rewind for a neat lay of the cable.
When pulling a heavy load place a blanket, jacket or tarpaulin over the cable about five or six feet behind the hook.In the event of a broken cable, this will slow the snap back of the cable and could prevent serious injury.
The winch clutch allows rapid unspooling of the cable from the cable drum for hooking onto the load. The clutch isoperated by the clutch shifter lever or air shifter.
WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD.
MANUAL CLUTCH SHIFTER (Refer to page 14)
TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the cable. Pull handle outand rotate 90°. With handle in the "DISENGAGED" position, cable may now be free-spooled from drum.
TO ENGAGE CLUTCH: Pull handle out, rotate 90° and release handle. Run the winch in reverse until the clutch han-dle snaps fully into the "ENGAGED" position. DO NOT attempt to pull a load unless the handle is fully at the"ENGAGED" position. If manual shift indicator light is present, the green light is lit when clutch is fully "ENGAGED".DO NOT attempt to pull a load unless the green light is lit.
AIR CYLINDER CLUTCH SHIFTER (Refer to page 15)
TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the cable. Apply air pres-sure to the .125-27 NPT port: 80 PSI (min.), 150 PSI (max.). CAUTION: Pressure must not exceed 150 PSI.
TO ENGAGE CLUTCH: Remove air pressure from the cylinder (a return spring engages the plunger). Run winch inreverse until the clutch engagement indicator light (green light) is lit. DO NOT attempt to pull a load unless the greenlight is lit. To connect light to the vehicle electrical system refer to the Electrical Schematic on page 15.
MAINTENANCE
1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with broken strands, replaceimmediately.
2. Check that the clutch is fully engaging. See OPERATION instructions, above,for the appropriate clutch shifter.FOR MANUAL CLUTCH ONLY: Monthly disengage clutch, put several drops of oil on the shaft and work clutch INand OUT several times to lubricate inside of clutch cylinder.
3. Check to see that drum cable does not overrun (BIRDNEST) when freespooling. Refer to page 5.
4. Replace drum bushings and seals if seals begin to seep grease. Refer to OVERHAUL INSTRUCTIONS, page 9.Add additional lubricant, Mobilith SHC 007, to gears if required.
7
CONDITION POSSIBLE CAUSE CORRECTION
Winch not mounted squarely, causing end bearings to bind up drum.
Check mounting. Refer to WINCH MOUNTING page 4.
Brake damaged. Inspect and replace brake.
Gears damaged. Inspect and replace damaged gears.
Load greater than rated capacity of winch. Refer to Specifications pg.3 for line pull rating.
Low hydraulic system pressure. Check pressure. SYSTEMS performance charts pg. 6.
Winch not mounted squarely, causing end bearing to bind up drum.
Check mounting. Refer to WINCH MOUNTING pg. 4.
Low hydraulic system flow rate. Check flow rate. Refer to HYDRAULIC SYSTEMS flow chart page 6.
Motor worn out. Replace motor.
Clutch not disengagedCheck OPERATION. Refer to page 7. Check ADJUSTMENT Refer to page 11.
Winch not mounted squarely, causing end bearings to bind drum.
Check mounting. Refer to WINCH MOUNTING pg. 4
CABLE BIRDNESTS WHEN CLUTCH IS DISENGAGED
Drag screw improperly adjusted. Adjust nylon drag screw. Refer to pg. 5.
Hydraulic system flow too highCheck flow rate. Refer to HYDRAULIC SYSTEMS flow chart pg. 6.
Drum in bind, winch not mounted squarely. Check mounting. Refer to WINCH MOUNTING pg. 4
Low hydraulic system flow. Check flow rate. Refer to HYDRAULIC SYSTEMS flow chart pg. 6.
Low hydraulic system relief pressure setting.Check relief valve setting. Refer to HYDRAULIC SYSTEMS pg. 6.
EXCESSIVE NOISE
DRUM CHATTERS, in
"REEL IN" direction
DRUM WILL NOT ROTATE AT NO LOAD
DRUM WILL NOT ROTATE UNDER LOAD
WINCH RUNS TOO SLOW
DRUM WILL NOT FREESPOOL
8
INSTRUCTIONS FOR OVERHAUL OF RAMSEY WINCHMODEL RPH 15,000
DISASSEMBLY
Take note of mounting configuration for proper mounting of parts during re-assembly. Replace all gaskets, o-rings,and seals with new ones during re-assembly.
Disconnect tube (item #44) from elbowson bottom of brake housing (item #7) andvalve (item #45). Remove motor (item#31) from brake housing (item #7) byunscrewing capscrews (item #20). Tapmotor lightly to disengage.
Remove coupling (item #25) from brakehousing. Examine coupling for signs ofwear, replace if necessary. If necessaryremove valve (item #45) from motor byremoving capscrews (item #16) and lock-washers (item #23). If valve is removedmake sure two square cross section O-rings remain seated in their counter boresin valve.
Remove brake housing (item #7) from endbearing (item #3) by unscrewing (6) cap-screws (item #20) in a criss-cross pattern(2 turns each) until all capscrews areremoved from brake housing. Remove brakeparts from brake housing. Examine brakediscs (item #27) for signs of wear andreplace if necessary. Examine O-rings (items#33 and #34) and backup O-rings (items#35 and #36)for signs of wear. Remove O-rings and backup O-rings from grooves inbrake piston (item #4).
Remove and examing springs (items #42and #43) for damage, replace if necessary.
Examine fitting (item #30) to assure that fit-tings are in proper working condition, replaceif necessary.
9
Remove tie plates (item #11) from end bearings (items #3 & #6) by unscrewing capscrews (item #18), asshown. Slide motor end bearing (item #3) from drum (item #1) and drum from gear housing end bearing (item#6). Remove input shaft (item #10) and thrust washers (items #47 & #50) from end bearings. Inspect gear teethand splined end of shaft (item #10) for signs of wear. If necessary replace shaft.
Remove o-ring (item #37) and bushing (item #14) from outside of motor end bearing (item #3), remove o-ring(item #32) and bearing (item #13) from inside of motor end bearing. Dip new o-ring (item #32) in oil and seat intogroove inside of end bearing and press new bearing (item #13) into end bearing. Press bushing (item #14) ontoend bearing and dip o-ring (item #37) in oil and seat into groove of end bearing.
Remove seal (item #40) from gear housing end bearing (item #6). Loosen nut (item #22) and remove nylonsetscrew (item #19) and remove ring gear (item #5) from gear housing end bearing. Remove bushing (item #14)and bearing (item #12) from gear housing end bearing (item #6). Press new bushing (item #14) and bearing (item#12) into place in end bearing. Install ring gear and nylon setscrew and nut. Ring gear must be fully seated in gearhousing end bearing (item #6)and slot in ring gear must bealigned with clutch shifter hole.Dip new seal in oil and install ingear housing end bearing, withsharp edge of seal outward.
10
Generously apply grease (MOBILITH SHC 007) to teeth of ring gear (item #5), teeth of planet gears in drum (item#1) and to bushing in end bearing (item #6). Apply grease to teeth of gear and short end of shaft (item #8).Place gear end of shaft through backside of drum (item #1) rotate shaft to mesh shaft gear with planet gear indrum. Apply grease to end of shaft and to I.D. and O.D. of bushing protruding from drum. Set thrust washer (item#50) over bushing and against drum. Place drum assembly into end bearing meshing planet gears with output gearon shaft and with ring gear in end bearing. End of drum shaft is placed into bearing pressed in end bearing (item#6).
Apply grease to O.D. of bushing protruding from drum. Set thrust washer (item #47) over bushing and againstdrum. Assemble motor end bearing (item #3) to drum assembly and use tie plates (item #11) and capscrews(item #18) to hold both end bearings together. Tighten capscrews to 173 Ft. Lbs. (235 Nm.). If necessary, removeand replace appropriate shifter assembly (item #2 or #3), as follows:
MANUAL CLUTCH SHIFTER ASSEMBLYRemove by loosening setscrew (item #21), jam nut and unscrewing clutch shifter. Be sure slot in ring gear is notaligned with clutch shifter hole in end bearing. Rotate drum, if necessary, to insure hole and slot are not aligned.Reinstall clutch shifter with plunger, jam nut and handle positioned in cylinder housing, as shown. Thread assembly(with handle engaged in cylinder slot) into the end bearing. Pull drum toward the gear housing end bearing toremove play. Hold drum in this position and continue threading the shifter assembly in until the gap between the endof the handle and cylinder is 7/16 +0
-1/16 inch and handle is in the horizontal position, as shown below. NOTE: Thisgap will vary with drum endplay. With the drum pulled against the gear housing, the gap should be 3/8 inch. Lightlytighten jam nut. Rotate drum until handle snaps fully into the engaged position. Pull handle out and rotate 90°.Verify that drum can be rotated freely (at least one full revolution) with clutch shifter at DISENGAGED position.Securely tighten jam nut while holding the handle. Tighten setscrew securely. Re-check clutch operation asdescribed on page 7.
AIR CYLINDER SHIFTER ASSEMBLYRemove by loosening setscrew (item #21), jam nut and unscrewing clutch shifter. To reinstall, thread air cylinderinto housing. Install one or two shims (item #44) under cylinder head, if needed, to orient air cylinder port for pneu-matic connections. Tighten setscrew. Refer to page 7 and check for proper operation of the clutch.
11
Set winch on gear housing end with motor end bearing up. Insert (6) springs (item #42) into pockets of motor endbearing. Install coupling (item #25) over splined end of shaft (item #8). Put (4) brake pins (item #9) into (4) holesin motor end bearing. Install well-oiled o-ring (items #33 and #34) and backup o-rings (items #35 and #36) intogrooves in O.D. of piston (item #4). Place o-rings into portions of grooves nearest center of piston in both cases.See Section A-A at right.
Piston (item #4), brake discs (item #27), and separator plates (item #39) must be clean and free of grease and oil.
Place piston over pins (item #9) and on top of springs (item #42). Place separator places (item #39) and brakediscs (item #27) alternately on top of piston, as shown. Press larger diameter end of (4) springs (item #43) intopockets in brake housing (item #7). Place gasket (item #28) on top of end bearing (item #4). Place brake housingover brake parts with fitting ports downward toward mounting feet. Align mounting holes and force brake housingdown onto end bearing (item #4). Apply 271 Loc-tite to 6 capscrews (item #17) and finger tighten until flush withsurface of brake housing. Tighten capscrews (2 turns each) in a criss-cross pattern until a torque of 30 ft-lbs. foreach capscrew is achieved.
12
Place gasket (item #29) into position on mounting surface of motor (item #31). Slide motor shaft into coupling andattach motor to brake housing (item #7). Use (2) capscrews (item #20) with lockwashers (item #24) and torque to87 ft.-lbs. (118 Nm) each. Securely connect tube (item #44) to elbows (item #26) in valve (item #45) and in bot-tom of brake housing.Apply at least 550 PSI hydraulic pressure to release brake and verify that brake releases by observing that the winchdrum rotates.
13
14
E
279,4
11.0
0
D
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120,7
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(2-P
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7/8
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19
LIMITED WARRANTY
RAMSEY WINCH warrants each new RAMSEY Winch to be free from defects in material and workmanship for a peri-od of one (1) year from date of purchase.
The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at theManufacturer's factory, or at a point designated by the Manufacturer, of such part that shall appear to theManufacturer, upon inspection of such part, to have been defective in material or workmanship.
This warranty does not obligate RAMSEY WINCH to bear the cost of labor or transportation charges in connectionwith the replacement or repair of defective parts, nor shall it apply to a product upon which repair or alterations havebeen made, unless authorized by Manufacturer, or for equipment misused, neglected or which has not been installedcorrectly.
RAMSEY WINCH shall in no event be liable for special or consequential damages. RAMSEY WINCH makes no war-ranty 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 throughchanges in design or materials as it may deem desirable without being obligated to incorporate such changes inproducts of prior manufacture.
If field service at the request of the Buyer is rendered and the fault is found not to be with RAMSEY WINCH's product,the Buyer shall pay the time and expense to the field representative. Bills for service, labor or other expenses thathave been incurred by the Buyer without approval or authorization by RAMSEY WINCH will not be acceptedSee warranty card for details.
RAMSEY WINCH COMPANY
Post Office Box 581510 Tulsa, Oklahoma 74158-1510Telephone: (918) 438-2760 FAX: (918) 438-6688Visit us on the web: www.ramsey.com
OM-914143-1206-D