Ramsey 256104 User Manual

INSTALLATION INSTRUCTIONS

FOR MODEL 6 LEVEL WINDER

KIT #256104

This Level Winder is designed specifically for the Ramsey Winch Model 600 Series Winches,
with standard length drums. These Models are 11.75 inches between drum flanges.

NOTE: If level winder is being installed on a car carrier (rollback), it is necessary to also
install Ramsey roller guide kit, part no. 256049. Failure to do so may cause damage or
breakage to the winch level winder or vehicle.

INSTALLATION PROCEDURE

Disengage the winch clutch and free spool all the cable off the winch and lay it in a line on the
ground behind the truck. Disconnect the end of the cable from the cable drum anchor. Drill .531
diameter holes through the horizontal flange of the forward most winch mounting angle as
shown in FIGURE 1.

VEHICLE CAB

WINCH MOUNTING
ANGLE

DRUM

DRILL .531 (17/32) DIA.
THRU. 2 PLACES

DRUM

600
SERIES WINCH

FIGURE 1

Insert the spring retainer into the springs so that the cleat at the center of the retainer will extend
toward the vehicle cab when the assembly is in place. Slide the retainer into the spring so that
the hole in the center of the retainer lines up with the hold down loop in the center of the spring.
Position the hole in the center of the retainer over the .531 diameter hole previously drilled in the
flange of the winch mounting angle. Loosely attach the spring retainer and spring to the flange
of the winch mounting angle using the 1/2 inch diameter capscrew, nut and lockwasher. After
making sure the spring and spring retainer are aligned squarely with the winch, as shown in
FIGURE 2, install the other capscrew, nut, and lockwasher through the other hole, and tighten
both capscrews securely so that the spring is clamped hard down onto the mounting surface.

NOTE:

The surface to which the spring is bolted must be 2.38 ± .50 inch above the

centerline of winch mounting bolts. See FIGURE 2, VIEW A-A.

RAMSEY WINCH COMPANY • P.O. BOX 581510 • TULSA, OKLAHOMA 74158

912586-0204-D

SPRING

SPRING RETAINER AND
MOUNTING HARDWARE

CLEAT

TENSIONER

HALF LOOPS ON ENDS OF SPRING
TANGS MUST SNAP INTO PLACE
OVER CROSSBAR OF TENSIONER.

SECTION

SHOWN ROTATED 90° CCW

15 ° (ON BARE DRUM)

TENSIONER
BAR MUST NOT TOUCH
CABLE WRAPPED AROUND
DRUM BARREL.

A-A

NOTE: CABLE MUST FEED
BETWEEN CENTER CROSS
BAR AND FRONT CROSS BAR
OF LEVEL WINDER

FIGURE 2

Insert the end of the cable into the opening of the tensioner so that it passes under the center
cross bar and over the front cross bar and install the cable into the cable anchor. Make a sharp
bend in the cable where it comes out of the cable anchor. Bring the tensioner up to the winch
and lift up first one then the other of the spring tangs while sliding the center cross bar of the
tensioner under the tangs. A pry bar will be necessary to lift up the tangs. Push the tensioner
toward the spring until the half loops at the end of each spring tang snap into place over the
center cross bar of the tensioner. See FIGURE 2.

Engage the clutch and run the winch in the reel in direction 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 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 surrounding structure, correct the problem.

CAUTION: STOP REEL IN OF CABLE BEFORE THIMBLE/HOOK ENTERS LEVEL
WINDER. FAILURE TO DO SO MAY CAUSE DAMAGE OR BREAKAGE TO THE
WINCH, LEVEL WINDER, OR VEHICLE.

OPERATION

Lay cable out in a straight line behind the truck to prevent kinking before beginning to wind in. It
is not necessary to walk in with the cable, let your Level Winder do the work.

PARTS LIST FOR #256104

PART
NO. QTY. DESCRIPTION

414558 2 CAPSCREW 1/2-13NC X 3 LG. HX.HD. ALL-THRD GR. 5, PLTD.
418069 2 NUT-HEX. 1/2-13NC REG. PLTD.
418218 2 LOCKWASHER 1/2 MED. SECT. PLTD.
434254 1 DECAL
494107 1 SPRING
688525 1 RETAINER SPRING
688517 1 TENSIONER-CABLE

RAMSEY WINCH COMPANY • P.O. BOX 581510 • TULSA, OKLAHOMA 74158

912586-0204-D