Ramsey H-930R User Manual
OPERATING, SERVICE, AND
MAINTENANCE MANUAL
MODEL H-930R
DOW-LOK
®
EQUIPPED
INDUSTRIAL LOW-MOUNT WINCH
PER SZUMMAR SPECIFICATIONS
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND
OPERATION OF WINCH. SEE WARNINGS!
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HYDRAULIC SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TYPICAL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TECHNIQUES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
AIR SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CABLE TENSIONER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WINCH MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ADJUSTING THE OIL COOLED WORM BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SERVICING THE OIL COOLED WORM BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
RE-ASSEMBLING AND CHECKING THE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TEST FOR PROPER BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
INSTRUCTIONS FOR OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16
DIMENSIONAL DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
PARTS LIST AND PART DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BACK COVER
RAMSEY MODEL H-930 DOW-LOK
®
PLEASE READ THIS MANU
AL CAREFULLY
This manual contains useful ideas in obtaining the most efficient operation from your Ramsey Winch, and safety procedures one needs to know before operating a Ramsey Winch. Do not operate this winch until you have carefully
read and understand the "WARNINGS" and "OPERATION" sections of this manual.
W
ARRANTY INFORMATION
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 our winch, please follow instructions for prompt service on all warranty claims. Refer to back
page for limited warranty.
SPECIFICA
TIONS (Conforms to SAE J706)*
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.
W
ARNINGS:
CLUTCH MUST BE TOTALLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.
DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH
DO NOT DISENGAGE CLUTCH UNDER LOAD.
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 PEOPLE.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.
CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD.
1
Rated Line Pull (lbs.)
…………………………………………………
30,000
(Kg.)
…………………………………………………
13,590
Gear Reduction
…………………………………………………………
41:1
Weight (without cable) …………………………………………522 lbs. (237 Kg.)
12345
lbs. 30,000 25,200 21,700 19,100 17,000
Kg. 13,600 11,430 9,840 8,660 7,710
ft. 25 55 85 135 185
m 7 16 28 41 56
FPM1112141617
MPM 3.3 3.6 4.3 4.9 5.2
* These specifications are based on recommended wire rope of 5/8" inch
(16mm) 6x19 extra improved plow steel
LAYER OF CABLE
*Rated line pull
per layer
*Cable Capacity
*Line Speed @
30 GPM
HYDRAULIC SYSTEM REQUIREMENTS
Refer to the performance char ts, below, to properly match your hydraulic system to the H-930 Model winch performance. The
charts consist of :
(1) Line pull (lb.) first layer vs. working pressure (PSI)
(2) Line speed, first layer (FPM) vs. gallons per minute (GPM).
Performance based on a motor displacement of 24 cubic inches with 30 GPM maximum flow rate. See page 17 for motor port
size.
H-930 Performance
30,000 lb. Duty Rating
41:1 Gear Ratio
2
LOW PRESSURE LINES
(.88 I.D. MINIMUM)
HIGH PRESSURE LINES
WINCH MOTOR
HYDRAULIC
LOW PRESSURE LINES
FLUID FILTER
RELIEF VALVE
PUMP
RESERVOIR
FLUID
4 WAY, 3 POSITION
CONTROL VALVE
(SUCTION)
PUMP INLET LINE
VALVE (CYLINDER SPOOL)
(1.31 I.D. MINIMUM)
GALLONS PER MINUTE
20
LINE PULL, LBS., FIRST LAYER
5,000
0
0
20,000
15,000
10,000
30,000
25,000
LINE SPEED, FPM, FIRST LAYER
3,000
WORKING PRESSURE, P.S.I.
2,0001,000 0
0
10
DYNAMIC
STATIC
5
10
15
30
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 freespooled off the drum. For winching in the load, the clutch must be fully engaged with the drum.
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.
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 engagement of the clutch before picking up the load. With this slack in the cable, exhaust
air pressure from the air shift cylinder and then run the winch in the "in" direction until the clutch springs into engagement and
the drum starts to turn. Clutch must be fully engaged before star ting the winching operation.
AIR SYSTEM REQUIREMENTS
The cable tensioner requires an independent, adjustable regulated air supply of between 50 and 90 PSI. An air regulator kit,
Ramsey Part No. 256092 is recommended.
CAUTION: DO NOT EXCEED 100 PSI TO THE CABLE TENSIONER ACTUATORS. THIS COULD CAUSE DAMAGE
TO THE ACTUATORS.
The inlet port of the air cylinder clutch requires a separate regulated air supply of 70-90 PSI.
CABLE TENSIONER OPERATION
If you remove 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, install the cable.
To adjust the free spool effort of the cable tensioner: Disengage the winch clutch and freespool 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.
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.
This Model H-930 winch is furnished with mounting angles. Angle size is 1/2” x 4 x 4 high strength steel angle.
3
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 with SAE 140 EP gear oil. 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 gases
may escape.
3. Lubricate cable with light oil.
B. MONTHLY
1. Lubricate the various grease fittings located in the cable drum, end bearing, clutch housing, or clutch operating linkage. Any
good grade of moly-disulfide containing grease 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. Use grade 5 or
better bolts.
4. Check the torque setting of the oil cooled worm brake. Make any adjustments required, following the procedure described
in Adjusting the Oil Cooled Worm Brake in this manual.
5. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.
C. ANNUALLY
1. Drain the oil from the winch annually or more often if winch is used frequently.
· After draining, fill the winch to the oil level plug with clean kerosene.
· Run the winch a few seconds with no load in the “Reel In” direction.
· Drain the kerosene completely from the winch.
· Refill the winch with 4 pints all purpose SAE 140 EP 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 and if necessary drain oil and remove cover for closer
inspection.
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. Insert the end of cable, opposite hook end, under drum and into the hole in drum barrel. Secure cable to drum barrel, using
setscrew furnished with winch. TIGHTEN SETSCREW SECURELY.
3. Carefully run winch in the “reel-in” direction. Keeping tension on end of cable, spool all the cable onto drum, taking care to
form neatly wrapped layers.
The wire rope can easily be removed from the drum by loosening the setscrew.
4
ADJUSTING THE OIL COOLED WORM BRAKE
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 then 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-930R Dow-Lok should be 65 to 75
ft. lbs. (90-100 Nm) 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.
SERVICING OF THE OIL COOLED WORM BRAKE
1. Remove the drain plug and drain the worm gear oil from the worm 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.
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.
c) Inspect the leaf spring. It should be bowed 1/8".
5
ADAPTER
CAP
NUT
TUBING
SOCKET
6
RE-ASSEMBLING AND CHECKING THE BRAKE
1. Press brake hub into place over worm shaft and key.
2. Assemble balls in slot #1 of cam. Use stiff grease to hold balls in place and slide cam over end of worm. Be sure that
balls are secure, between cam slots and hub slots.
3. Install brake disc.
4. Install retainer plate, smooth side toward brake disc.
5. Install the gasket on the cover with a small amount of grease or sealer.
6. The coil spring goes over the adjusting screw on the inside of the cover.
7. 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.
8. Install brake housing cover, making sure the protruding pins go through the leaf spring and into the holes in the retainer
plate.
9. Bolt cover into place with the mounting screws. Apply Loc-tite PST #567 thread sealer to drain plug, install drain plug and
add 4 pints all purpose SAE 140 EP gear oil. Refer to Instructions for Overhaul for more information on assembling winch.
10. Turn winch in the hoisting direction at least one turn of the input shaft.
11. Turn the adjusting screw in until it is finger tight. Tighten jam nut to lock adjusting screw.
TEST FOR PROPER BRAKE ASSEMBLY
After the brake has been adjusted to the proper torque setting 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 safety brake housing. If housing is not hot to the touch then run winch in the reverse direction (cable
out) for one minute. Brake housing should begin to heat.
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, confirm that the balls are in
slot #1 of cam, 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
PIN
A
BRAKE DISC
(LOOKING AT CAM
PLATE FROM WINCH)
VIEW
A-A
1
2
1
2
COMPOSITION
A
BALL
HUB
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