OPERATING, SERVICE
AND MAINTENANCE MANUAL
MODEL HD-234
RAM-LOK® EQUIPPED
INDUSTRIAL LOW-MOUNT WINCHES
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 TECHNIQUES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 WINCH MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 HYDRAULIC SYSTEMS/PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . .8 TYPICAL LAYOUT/HYD. SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . .8 TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
INSTRUCTIONS FOR OVERHAUL OF
RAMSEY MODEL HD-234 RAM-LOK® WINCH
DIS-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13 RE-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16
DIMENSIONAL DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19 PARTS LIST AND PARTS DRAWING . . . . . . . . . . . . . . . . . . . . . . . . .20-23 LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BACK COVER
RAMSEY WINCH MODEL HD-234 RAM-LOK®
PLEASE READ THIS MANUAL 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.
WARRANTY 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 your winch, please follow instructions for prompt service on all warranty claims. Refer to back page for limited warranty.
SPECIFICATIONS: CONFORMS TO SAE J706*
. . . . . . .Rated Line Pull (lbs.) |
. . . . . . . |
. |
. . . . . . . . . . |
. . . . . . . . . . |
. . 8,000 |
|
(kg) . . . . . . . . |
. . . . . . |
. |
. . . . . . . . . . |
. . . . . . . . . . |
3,620. . |
|
Gear Reduction . . . . . . . . . . . |
. . . . . . |
. |
. . . . . . . . . . |
. . . . . . . . . . |
34:1. . . |
|
Weight HD-234 . . . . . . . . . . . . |
. . . . . . |
. |
. . . . . . . . . . |
. . . . . 110lbs. (50 kg) |
|
|
HYD-234 . . . . . . . . . . . |
. . . . . . |
. |
. . . . . . . . . . |
. . . . .105 lbs. (48 kg) |
|
|
LAYER OF CABLE |
|
|
1 |
2 |
3 |
4 |
|
|
|
|
|
|
|
*Rated line pull |
lbs. |
|
8,000 |
6,700 |
5,700 |
5,000 |
per layer |
kg |
|
3,620 |
3,030 |
2,610 |
2,290 |
|
|
|
|
|
|
|
**Long Drum |
ft. |
|
25 |
60 |
95 |
140 |
Cable capacity |
m |
|
8 |
18 |
30 |
43 |
**Short “Y” Drum |
ft. |
|
15 |
30 |
55 |
75 |
Cable capacity |
m |
|
4 |
9 |
16 |
22 |
|
|
|
|
|
|
|
**Line speed |
FPM |
|
28 |
34 |
39 |
44 |
|
MPM |
|
8,6 |
10,1 |
11,7 |
13,4 |
|
|
|
|
|
|
|
* Winch only conforms to SAE J706. For SAE qualification of mounting angles, if applicable, consult Ramsey Engineering
** These specifications are based on recommended wire rope of 3/8 inch diameter extra improved plow steel or equivalent.
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.
4
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.
When pulling a load where there is even a remote chance of cable failure, place a blanket, jacket or tarpaulin over the cable about six feet behind the hook. This will slow the snap back of a broken cable and could prevent serious injury.
NOTE: The Ramsey level winder is an available accessory for tightly respooling unloaded cable onto the drum.
The Ram-Lok® semi-automatic clutch allows rapid unspooling of the cable, from cable drum, for hooking onto the load.
The Manual “T-Handle” clutch is operated as follows:
1.TO DISENGAGE CLUTCH, run the winch in the reverse (reel out) direction until the load is off the cable. Pull outward on the T-handle, rotate it counter-clockwise 90° and release. The clutch is now locked out and the cable may be pulled off by hand.
2.TO ENGAGE CLUTCH, pull outward on the handle, rotate it clockwise 90° and release. Run the winch in reverse until the shifter knob snaps fully in or until the cable drum starts turning. At this point make sure the shifter knob is all the way in. The plastic plug in top of clutch housing may be removed, for inspection of clutch to assure total engagement. After the clutch is fully engaged, the winch is ready for winching in the cable.
The Air Shifter clutch is operated as follows:
1.TO DISENGAGE CLUTCH, run the winch in reverse (reel out) direction until the load is off the cable. Apply 60-125 PSI to inlet port fitting of air cylinder. Run winch in the forward (reel in) direction to disengage clutch.
2.TO ENGAGE CLUTCH, remove air pressure from air cylinder. Run the winch in reverse until the cable drum starts turning. The plastic plug in top of clutch housing may be removed, for inspection of clutch to assure total engagement. After the clutch is fully engaged, the winch is ready for winching in the cable.
5
WARNINGS
CLUTCH MUST BE TOTALLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.
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.
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 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 sliding clutch—ensure it is fully engaging and disengaging with the cable drum. To observe if the clutch is fully engaging, remove the plastic plug in top of the housing. If clutch is not fully engaging:
•Inspect clutch shifter assembly parts, check for damage or excessive wear and replace as necessary.
•Observe the jaws on both the clutch and cable drum, checking for rounding of the driving faces. If rounding has occurred they should be replaced immediately.
3.Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are loose. Make sure to use only SAE grade 5 bolts or better.
4.Check alignment of chain and sprockets and adjust as required to minimize wear.
5.Inspect the cable. If the cable has become frayed with broken strands, replace immediately.
6
C. ANNUALLY
1.Drain the oil from the winch annually or more often if winch is used frequently.
2.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.
3.Refill the winch to the oil level plug with Phillips SMP 80W-90, Mobil HD 80W-90, Shell Spirax HD 80W-90, or CITGO MP 80W-90 gear oil only.
4.Inspect frame and surrounding structure for cracks or deformation.
5.Gear wear can be estimated by rocking the drum back and forth and 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 (clutch housing end, cable drum, and gear housing end) are properly aligned. All standard model HD-234 series winches are furnished with recommended mounting angles. Angle size is 1/4 x 2-1/2 x 2-1/2 x 36” long high strength steel angle.
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, into the 7/16" dia. 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 the cable drum, taking care to form neatly wrapped layers.
7
HYDRAULIC SYSTEMS
Refer to performance charts, below, to properly match your hydraulic system to the HD-234 winch performance. The charts consist of:
1.Line pull (lbs.) first layer vs. working pressure (PSI). STATIC (solid line) refers to hoisting a suspended load from rest; DYNAMIC (dashed line) refers to maintaining the motion of a moving load.
2.Line speed, first layer (FPM) vs. gallons per minute (GPM).
Performance based on a motor displacement of 3.6 cubic inches with 15 GPM maximum flow rate.
HD-234 PERFORMANCE
8,000 LB. DUTY RATING - 34:1 GEAR RATIO
8,000 |
|
7,000 |
DYNAMIC |
5,000 |
|
6,000 |
|
PULL,LINELBS |
|
3,000 |
STATIC |
LAYERFIRST |
4,000 |
|
|
2,000 |
|
||
|
|
|
|
|
|
1,000 |
|
01000 2000 3000
WORKING PRESSURE, PSI
|
35 |
|
|
30 |
|
|
25 |
|
FPMSPEED,LINE LAYERFIRST |
20 |
|
15 |
||
|
||
|
10 |
5
0
0 |
5 |
10 |
15 |
FLOW, GPM
8
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