Ramsey H-800 User Manual

Ramsey Winch Company

OWNER'S MANUAL

MODEL H-800 SERIES

DOW-LOK

EQUIPPED

INDUSTRIAL LOW-MOUNT WINCH

Congratulations

Ramsey Winches are designed and built to exacting specifications. Great care and skill go into every winch we make. If the need should arise, warranty procedure is outlined on the back of your self-addressed postage paid warranty card. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company. If you have any problems with your winch, please follow instructions for prompt service on all warranty claims. Refer to back page for limited warranty.

CAUTION: Read and understand this manual before installation and operation of winch. See Safety Precautions.

Rated Line Pull (lbs.)

……………………………………………………

20,000

(Kg.)

……………………………………………………

9,060

Gear Reduction

……………………………………………………………

40:1

Worm RPM …………………….…………………………. 460 @ 30 GPM

Weight (without cable) ………………………………………. 485 lbs. (220 Kg)

12345**

lbs. 20,000 16,600 14,200 12,400 11,000

Kg. 9,060 7,510 6430 5,610 4,980

ft. 35 75 125 180 240

m1022385472

FPM1822262933

MPM 5.4 6.6 7.9 8.8 10.0

Note: The rated line pulls shown are for the winch only. Consult wire rope manufacturer for wire rope ratings.

** Fifth Layer does not c onform to SAE J706

* These specifications are based on recommended wire rope of .63 inch (16 mm) dia. 6x19 extra improved plow steel or equivalent

LAYER OF CABLE

*Rated line pull per layer

*Cable Capacity

*Line Speed

Safety Precautions To Guard Against Possible Injury

A. Clutch must be totally engaged before starting the winch operation.

B. Do not disengage clutch under load.

C. Stay out from under and away from raised loads.

D. Stand clear of cable while pulling. Do not try to guide cable.

E. Do not exceed maximum line pull ratings shown in specifications.

F. Do not use winch to lift, support, or otherwise transport people.

G. A minimum of 5 wraps of cable around the drum barrel is necessary to hold load. Cable set screw is not

designed to hold load.

Performance Specifications . . . . . . . . . . . . . .COVER

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . .2

Techniques of Operation . . . . . . . . . . . . . . . . . . . . .3

Winch Maintenance . . . . . . . . . . . . . . . . . . . . . . . .3

Winch Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Worm Brake Maintenance . . . . . . . . . . . . . . . . . . . .5

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Test for Proper Assembly . . . . . . . . . . . . . . . . . . .6

Checking Assembly Arrangement and Setting . . . .7

Adjustment of Clutch Air Shifter . . . . . . . . . . . . . . .7

Hydraulic System Requirements . . . . . . . . . . . . . . .8

Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . .9

Instructions for Overhaul . . . . . . . . . . . . . . . . .10-16

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .10-13

Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . .13-16

Cable Tensioner Overhaul . . . . . . . . . . . . . . . . . .17

Dimensional Drawings . . . . . . . . . . . . . . . . . . .18-19

Parts List and Parts Drawing . . . . . . . . . . . . . .20-23

Warranty . . . . . . . . . . . . . . . . . . . . . . .BACK COVER

Contents

TECHNIQUES OF OPERATION

The best way to get acquainted with how your winch operates is to make test runs before you actually use it. Plan your test in advance. Remember, you hear your winch, as well as see it operate. Get to recognize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Gain confidence in operating your winch and its use will become second nature with you.

The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pileup on one end of drum. If this happens reverse the winch to relieve the load and move your anchor point further to the center of the vehicle. After the job is done you can unspool and rewind for a neat lay of the cable.

The Dow-lok® clutch provides free-spooling and clutch engagement with the cable drum. With the clutch disengaged, the cable can be free-spooled off the drum. For winching in the load the clutch must be fully engaged with the drum.

The clutch is latched into either the engaged “IN” position, or the disengaged “OUT” position, by a pin at the bottom of the shifter handle which fits into the latching slots.

TO UNLATCH CLUTCH

Run winch in the reverse (reel out) direction until the load is off the cable, grasp handle firmly and while pushing on the top of the handle with the thumb for leverage, lift until pin clears latching slots.

TO ENGAGE THE CLUTCH

Unlatch and pull handle toward the “IN” position as far as it will go. In order to attain full engagement, internal elements of the clutch must be aligned. This alignment will take place when the cable drum or cable drum shaft turns a maximum of 1/4 revolution. The clutch will automatically spring into engagement and pin will drop into “IN” slots when this alignment takes place. Do not attempt to lift a load unless pin is fully into “IN” slots. Keep clear of

spring-loaded handle during automatic engagement. TO DISENGAGE THE CLUTCH Unlatch and push handle to “OUT” position and fully insert pin into latching slots. Do not disengage the clutch

under load.

The Dow-lok®air-shifter clutch provides free-spooling and clutch engagement with the cable drum. With the

clutch disengaged, the cable can be free-spooled off the drum. For winching in the load, the clutch must be fully engaged with the drum.

TO ENGAGE THE CLUTCH

There must be a minimum of 1 foot of slack in the cable before attempting to engage the clutch. This will allow the drum to rotate a minimum of 1/4 turn allowing the engagement of the clutch before picking up the load. With this slack in the cable, exhaust air pressure from the air shift cylinder. Run the winch in the “IN” direction until the clutch starts to turn. Clutch must be fully engaged before starting the winch operation.

TO DISENGAGE THE CLUTCH

Run winch in the “OUT” direction until there is no load on the cable. Apply 70-90 psi to the air shift cylinder to disengage the clutch. Do not disengage the clutch under load.

WINCH 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 in top of the gear housing. Be sure that it is in good operating condition so that hot oil gasses may escape.

3. Lubricate cable with light oil.

B. MONTHLY

1. Lubricate the various grease fittings located in the ends of cable drum shaft, end bearing, clutch housing or clutch operating linkage. Any good grade of grease containing moly-disulfide is acceptable.

2. Check the action of the locking ring. Make sure it is spring loaded and free to move fully against the cable drum in the engaged position and that it is pulled fully away from the cable drum and latched when disengaged.

3. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are loose. Make sure to use only grade 5 bolts or better.

4. Check the torque setting of the oil cooled worm brake. Make any adjustments required, following the procedure described in “Worm Brake Maintenance” in the Owner's Manual.

5. Check alignment of chain and sprockets and adjust as required to minimize wear.

6. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.

C. ANNUALLY

1. Perform the following annually or more often if winch is used frequently:

• Drain the oil from the winch.

• Fill the winch to the oil level plug with clean kerosene.

• Run the winch a few minutes with no load in the reel in direction.

• Drain the kerosene from the winch.

• Refill the winch to the oil level plug with all purpose E.P. 140 gear oil.

2. Inspect frame and surrounding structure for cracks or deformation.

3. Gear wear can be estimated by rocking the drum back and forth. If necessary, drain oil and remove cover for closer inspection.

WINCH MOUNTING

It is most important that this winch be mounted securely so that the three major sections (the clutch housing end, the cable drum and the gear-housing end) are properly aligned.

All standard H-800 Dow-Lok®series winches are furnished with recommended mounting angles. Angle size is 1/2 x 3 x 4 high strength steel angle.

CABLE INSTALLATION

The Ramsey Model H-800 "Dow-Lok"® winch has two tapered pockets cast into the drum. One pocket is for installations with the wire rope wound over the drum. The other pocket is for an underwound wire rope.

1. Slide the wire rope through narrow end of the pocket against the drum flange.

2. Wrap the wire rope around the anchor "puck" and pull the wire rope and anchor back into the wide end of the pocket.

3. Use a soft hammer to drive the back side of the wire rope, firmly seating the wire rope and anchor, into the pocket.

The wire rope can easily be removed from the drum by driving the anchor out the wide end of the pocket.

WORM BRAKE MAINTENANCE

ADJUSTMENT

The oil cooled, fully adjustable, automatic worm brake operates in the worm housing lubricant, all parts being submerged in oil. When the brake wears to the point that the load begins to drift, the brake can be adjusted as follows:

1. Loosen the adjusting screw lock nut.

2. Tighten the brake by turning the adjusting screw clockwise. CAUTION: Only 1/4 turn is usually required to adjust the brake. Over-tightening can cause over-heating, and damage to the brake parts. Tighten the lock nut after adjustment is completed.

If the brake does not respond to adjustment then a new leaf spring and brake disc is needed. A torque wrench can be equipped with a special adapter

to fit the input shaft (worm) of the winch. The adapter can be made by welding a nut to the end of a piece of tubing as shown in the following figure.

After welding the cap and nut to the tubing, slot the tubing, as shown. This will allow the special adapter to slide over the keyway and will then act as a large socket. A torque wrench can the be used to apply the proper torque. Turn the torque wrench so that the drum turns in the spool out direction or lowering direction. The torque

rating for the brake on the Model H-800 Dow-Lok

should be 50 to 55 ft-lbs. If torque wrench does not show the proper value as it turns, then the worm brake adjusting bolt should be turned clockwise 1/4 turn. Each time the adjusting bolt is turned, check the torque reading. Continue this procedure until the proper torque reading is achieved. Then tighten the lock nut.

DIS-ASSEMBLY

1. Remove the drain plug and drain the worm gear oil from the gear housing.

2. Back off the lock nut, then the adjusting screw, both two turns or more by turning them counter-clockwise.

3. Remove the cover mounting screws.

4. Remove the cover along with coil spring and leaf spring.

5. Remove the retainer plate, composition brake disc, cam plate and balls. Note which slots balls are in.

6. Inspect parts as follows: a) Composition brake discs are 1/4" thick when new. Replace if thinner than 3/16” or if surfaces are glazed or

burnt.

b) Inspect the flat, ground surface of the cam plate and retainer plate for glazing, warpage, or other damage.

Glazing can be removed by scraping carefully. Otherwise replace cam plate or retainer plate.

c) Inspect the leaf spring. It should be bowed 1/8". Replace leaf spring if flattened.

ADAPTER

CAP

NUT

TUBING

SOCKET

RE-ASSEMBLY

1. Press brake hub into place over worm shaft and key.

2. Assemble balls in #2 slots of cam. Use stiff grease to hold balls into place and slide cam over end of worm. Be sure that balls are secure, between cam slots and hub slots.

3. Install retainer plate, smooth side toward brake disc.

4. Install the gasket on the cover with a small amount of grease or sealer.

5. The coil spring goes over the adjusting screw on the inside of the cover.

6. Install the notches of the leaf spring on the pins protruding through the cover. The hollow side of the leaf spring goes toward the brake.

7. Install brake housing cover, making sure the protruding pins go through the leaf spring and into the holes in the retainer plate.

8. Bolt cover into place with the mounting screws. Install drain plug and add 3-3/4 pints all purpose E.P. 140 oil.

9. Turn winch in the hoisting direction at least one turn of the input shaft.

10. Turn the adjusting screw in until it is finger tight.

TEST FOR PROPER BRAKE ASSEMBLY

After the brake has been adjusted to the proper torque setting (see Adjustment section above), disengage clutch. Start vehicle engine and run winch in the reel in (hoisting direction). Allow winch to run in this direction for one minute.

Place your hand on the brake housing. If housing is not hot to the touch, run winch in the reverse direction (cable out) for one minute. Brake housing should be hot to the touch.

When these conditions exist, proper installation has been made. If heating becomes noticeable when running the winch in forward rotation (hoisting direction), the brake should be again disassembled. When disassembled, place the brake balls in the alternate set of slots in the cam plates, then carefully follow the instructions for re-assembling and checking the brake.

WORM BRAKE

LEAF SPRING

COIL SPRING

BRAKE HOUSING

COVER MOUNTING SCREW

ADJUSTING SCREW

DIAGRAM 1

BRAKE COVER

THREAD SEAL

JAM NUT

RETAINER PLATE

CAM PLATE

GASKET

BRAKE DISC

(LOOKING AT CAM

PLATE FROM WINCH)

VIEW

A-A

COMPOSITION

BALL

HUB

CLUTCH AIR SHIFTER ADJUSTMENT

1. Place winch assembly back into mounting frame and reattach using (8) mounting bolts and lockwashers. Torque mounting hardware to 290 ft. lbs. each. Make sure that gear housing and clutch housing are not rubbing against drum flanges.

2. Place air shifter assembly #5 over shifter shaft aligning clevis over flats of shaft. Secure clevis to shaft using clevis pin #76 and cotter pin #75. Place shifter shaft in the "ENGAGED" position. With the air cylinder shaft fully retracted, push shifter assembly toward the drum until all play is taken out of the shifter shaft. Secure shifter assembly to clutch housing using (4) capscrews #46 (flanged hx. hd. serrated). Tighten securely, but do not torque.

3. Hook up air (70 to 90 psi) to inlet port of air cylinder and disengage clutch. Look into the opening in the clutch housing and verify that the locking ring and retainer plate are not making contact. Locking ring and retainer plate must not make contact. There must be a clearance (gap) of .09 inch (max.) between the locking ring and retainer plate when the winch is fully disengaged. If there is contact, the (4) capscrews #46 should be loosened and the plate pulled away from the drum approximately .06 inch. Tighten screws securely and check action to assure needed clearance. Repeat adjustment procedure as needed to acquire needed gap. Shift clutch 2 or 3 times to verify proper shifting of clutch. After final adjustment, torque (4) capscrews #46 to 18 ft. lbs. each. Attach cover #43 using (4) capscrews #61.

PLATE

RETAINER

LOCKING RING

.09 MAX.

WINCH ASSEMBLY

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts, below, to properly match your hydraulic system to H-800 Dow-Lok®winch performance. The charts consist of :

(1) Line pull (lb.) first layer vs. working pressure (PSI). STATIC (solid line) refers to hoisting a suspended load from

rest; DYNAMIC (dotted line) refers to maintaining the motion of a moving load. (2) Line speed, first layer (FPM) vs. Flow, gallons per minute (GPM). Performance based on a motor displacement of 14.9 cubic inches with 30 GPM maximum flow rate. See page 17

for motor port size.

H-800 Series Performance 20,000 lb. Duty Rating 40:1 Gear Ratio

TYPICAL HYDRAULIC LAYOUT

WORKING PRESSURE, PSI

LINE PULL, LBS

FIRST LAYER

6,000

8,000

10000

12,000

14,000

16,000

STATIC

DYNAMIC

20001000 3000

FLOW, GPM

LINE SPEED, FPM

FIRST LAYER

20 30

18,000

20,000

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