Ramsey HDGY-350R User Manual

OPERATING SERVICE AND

MAINTENANCE MANUAL

MODEL HDG 350 RAM-LOK

®

INDUSTRIAL LOW-MOUNT

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE

INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!

TABLE OF CONTENTS

INTRODUCTION .................................................................................................................................... 1

WARRANTY INFORMATION ................................................................................................................... 1

SPECIFICATION .................................................................................................................................... 1

TECHNIQUES OF OPERATION ................................................................................................................ 2

WARNINGS ........................................................................................................................................... 2

WINCH MAINTENANCE ......................................................................................................................... 3

CABLE INSTALLATION ........................................................................................................................... 3

HYDRAULIC SYSTEMS / PERFORMANCE CHARTS .................................................................................. 4

TYPICAL LAYOUT / HYD. SYSTEM DIAGRAM .......................................................................................... 4

TROUBLE SHOOTING GUIDE .................................................................................................................. 5

INSTRUCTIONS FOR OVERHAUL

DIS-ASSEMBLY ............................................................................................................................. 5-8

RE-ASSEMBLY ............................................................................................................................ 8-10

ADJUSTING THE OIL COOLED BRAKE .................................................................................................. 11

SERVICING THE OIL COOLED BRAKE ................................................................................................... 12

RE-ASSEMBLING AND CHECKING THE BRAKE ..................................................................................... 13

TEST FOR PROPER BRAKE ASSEMBLY ................................................................................................ 13

DIMENSIONAL DRAWING .................................................................................................................... 14

PARTS LISTS & PARTS DRAWINGS ................................................................................................. 15-17

LIMITED WARRANTY ........................................................................................................... BA CK COVER

RAMSEYWINCHMODELHDG‐350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 self­addressed 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) ................................................................ 10,000

(Kg) .................................................................. 4,536

Gear Reduction ................................................................................. 30:1

Weight (without cable) ...................................................... 110 lbs (50 Kg)

Duty Cycle (ft) ....................................................................... 183

LAYER OF CABLE 1 2 3 4**

*Rated line pull

per layer

*Cable Capacity

*Line Speed
(at 15 GPM)

*These specifications are based on recommended wire rope of .44 inch

dia. extra improved plow steel or equivalent

**Does not conform to SAE J706 specifications.

lbs 10,000 8,100 6,900 6,000

Kg 4,530 3,670 3,120 2,720

ft 10 30 45 70

m 4 9 15 21

FPM 26 31 36 41

MPM 7.9 9.4 10.9 12.4

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

1

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

hooking onto the load. The clutch is operated by the “T-handle”, located on the end of the winch as
follows:

®

semi-automatic clutch allows rapid unspooling of the cable, from cable drum, for

1. TO DISENGAGE CLUTCH, run the winch in the reverse (reel out) direction until the load is off the

cable. Pull outward on the clutch 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 counter-clockwise 90° and release.

Run the winch in reverse until the clutch handle snaps fully in or until the cable drum stops turning.
At this point make sure the clutch handle 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.

WARNINGS

CLUTCH MUST BE TOTALLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.
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 PEOPLE.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.

CABLE SETSCREW IS NOT DESIGNED TO HOLD LOAD

2

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 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, making sure it is fully engaging and disengaging with the cable

drum. Remove the plastic plug in top of the housing and observe if the clutch is fully engaging. 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 grade 5 bolts or better.

4. 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.

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 all purpose E.P. 140 gear oil.

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.



CABLE INSTALLATION

There are 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 under-wound wire rope.

When properly used, the wedge pocket design is one of the most secure anchoring methods available.

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

3. Wrap the wire rope around the anchor “puck” and pull the wire rope and anchor back into the wide end of

the pocket.

4. 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.

3

HYDRAULIC SYSTEMS

Refer to performance charts, below, to properly match your hydraulic system to the HDG-350 winch
performance. The charts consist of:

1. Line pull (lbs.) first layer vs. working pressure (P.S.I.). STATIC refers to lifting a suspended load

from rest; DYNAMIC refers to maintaining the motion of a moving load.

2. Line speed, first layer (F.P.M.) vs. gallons per minute (G.P.M.).

Performance based on a motor displacement of 4.5 cubic inches with 15 GPM maximum flow rate.

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4

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TROUBLE SHOOTING GUIDE

CONDITION POSSIBLE CAUSE CORRECTION

Clutch inoperative or binds up. 1. Dry or rusted shaft.

2. Bent yoke or linkage.

3. Clutch jaws are in contact

Oil leaks from housing 1. Seal damaged or worn.

2. Too much oil.

3. Clutch jaws are in contact.

Winch runs too slow 1. Hydraulic motor worn out.

2. Low flow rate.

Cable birdnests when clutch is
disengaged.

Hydraulic fluid leaks out hole in
motor adapter.

1. Drag brake disc worn. 1. Replace discs.

1. Hydraulic motor shaft seal
damaged.

1. Clean and lubricate.

2. Replace yoke or shaft
assembly.

3. See Techniques of Operation

1. Replace seal.

2. Drain excess oil. Refer to
Techniques of Operation.

3. Replace gasket.

1. Replace motor.

2. Check flow rate. Refer to
Hydraulic Systems flow
chart, page 4.

1. Replace seal.

INSTRUCTIONS FOR OVERHAUL OF HDG-350

DIS-ASSEMBLY

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

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1. Drain oil from gear housing by removing

plug #38 from bottom of gear housing.
Remove plugs #35 & #37 from top of
gear housing. Remove handle #10 by
driving pin #39 from shifter shaft of winch.

10

39

35

37

38

5



2. Remove clutch housing #12 and clutch

#5 from winch assembly.

Remove two keys #32 from keyways. A
screwdriver can be used, at notch, to aid in
the removal of keys. Once keys have been
removed, drum #8 and thrust washer #47
can be removed from drum shaft.

3. Remove motor #36 and coupling #6 from

adapter #2 by unscrewing two capscrews
#24 with lockwasher #28.

Remove keys #13 from worm shaft.
Unscrew four capscrews #23 and remove
adapter #2 from gear housing. Replace
adapter seal #42 and gasket #30.

4. See page 12 for servicing the oil cooled

brake. Remove brake housing mounting
screws #22 and remove brake with
gasket. Replace gasket #30. Remove
worm #15 and bearings #16 from gear
housing. Use soft hammer to gently tap
input end of worm and drive worm and
bearing from gear housing. Once worm
has been removed from housing, bearing
can be pressed from end of worm.

Check for signs of wear or damage to
worm #15 and bearing #16. Replace if
necessary.

6

5. Remove gear housing cover #7 from gear

housing #11 by unscrewing capscrews
#19. Thread two of the capscrews into
the two tapped holes of cover and tighten.
This will pull the cover loose from gear
housing.

Remove cover gasket #31 and pull shaft
#14, with gear attached, and thrust
washer #47 from gear housing.

6. Check for signs of wear on gear teeth. If

replacement of gear is necessary, replace
as follows:

a. Press gear #9 from shaft #14.
b. Examine shaft keys and keyways.

If distortion of keys and/or keyways
is evident, shaft and keys should be
replaced.

c. Use a soft hammer to gently tap keys

#33 into keyways. Press gear #9
over shaft and keys. Gear must be
centered over keys.

7. Remove seal #43 from back of #11 gear

housing. Press bushing #18 from gear
housing. Press new bushing and seal back
into place.

8. Check drum bushings #17 for signs of

wear. Replace if necessary by pressing
old bushings from drum. Press new ones
into place.

7

9. Examine shifter assembly #1 for damage

to yoke. Yoke should be firmly attached to
shaft, yet able to swivel freely around shaft.
Replace if necessary.

Install new shifter assembly #1 by placing
end of shaft, opposite yoke, through spring
#45 and into housing #12.

10. Check cover bushing #17 for signs of

wear. If necessary remove old bushing
and press bushing into place.

11. Apply grease to end of shaft, opposite

gear. Apply grease to bushing in gear
housing #11. Place greased end of shaft
through thrust washer #47 and bushing in
gear housing #11. Place gasket #31 onto
gear housing cover #7. Apply grease to
gear end of shaft and cover bushing. Place
cover onto shaft and secure to housing
with ten #19 capscrews. Tighten
capscrews to 8 ft. lbs. (10.8 Nm) each.

12. Press bearing #16 onto worm #15.

NOTE: Be sure that thick shoulder of
bearings outer race (side with
manufacturer's name and part number) is
out, away from worm threads. Press
bearing and worm into gear housing. Slip
new gasket #30 onto brake housing. Use
four capscrews #22 to secure brake
housing to gear housing. TIGHTEN
CAPSCREWS TO 8 FT. LBS. (10.8 Nm.)
EACH. See re-assembling and checking
the brake on page 13 to complete brake
assembly.

8

13. Press bearing #16 onto worm and into

housing. NOTE: Be sure that thick
shoulder of bearings outer race (side with
manufacturer's name and part number) is
out, away from worm threads. Place
gasket #30 onto adapter #2. Attach
adapter to gear housing using four (4)
capscrews #23. TIGHTEN CAPSCREWS
TO 12 FT. LBS. (16.3 Nm.) EACH. Insert
keys #13 into keyways of worm shaft.
Slide tapered end of coupling #6 over end
of worm shaft. Be sure roll pin #39 is in
coupling.

Place motor shaft, with key in keyway, into
coupling. Secure motor to adapter, using
two (2) capscrews #24 and lockwashers
#28. TIGHTEN CAPSCREWS TO 75 FT.
LBS. (102 Nm.) EACH.

14. Place winch with gear housing cover down

on work bench. Drum shaft should be in
vertical position. Slide thrust washer #46
over drum shaft and slide downward until
washer rests on gear housing. Set springs
#44 into pockets of gear housing with
drag brakes #29 on top of springs. Slide
drum assembly #8 onto drum shaft with
drum jaws upward.

9

15. Place thrust washer #47 over end of drum

shaft and slide downward until spacer rests
on drum. Press drum downward to
compress springs in gear housing.

Insert keys #32 into keyways with sharp
edge of keys pointing outward and notched
end of keys upward. A rubber or brass
mallet will be needed to gently tap keys into
position.

Apply grease to keys and end of shaft.
Place jaw clutch #5 over end of shaft and
slide jaw clutch over keys.

Set clutch housing #12 over end of drum
shaft. Pull jaw clutch #5 upward, toward
clutch housing, enough to allow yoke, in
clutch housing, to fit properly in groove
around jaw clutch.

16. Insert plug #38 into bottom of gear

housing. Permatex may be applied to
threads to help prevent leakage.

Attach handle #10 to clutch shaft using
pin #39.

Pour 1 pint of SAE 140 EP gear oil into
housing through hole in top of housing.
Insert relief fitting #35 into reducer #37.
Reducer should then be placed into hole on
top of gear housing. Tighten fitting and
reducer securely.

39

10

35

37

38

10

ADJUSTING THE OIL COOLED WORM BRAKE

The oil-cooled, fully adjustable, automatic 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 lock nut on the adjusting screw.

2. Tighten the brake by turning the adjusting screw clockwise. CAUTION: Only ¼ turn is usually
required to adjust the brake. Over-tightening can cause overheating, 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 below.

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 Model HDG-350 should be 9 to 15 ft. lbs. If the torque wrench does
not show the proper value as it turns, then the worm brake adjusting bolt should be turned clockwise ¼
turn to increase the torque setting. 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.

11

SERVICING OF THE OIL COOLED BRAKE

1. Back off the lock nut, then the adjusting screw, both two turns or more by turning them counter­clockwise.

2. Remove the cover mounting screws.

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



4. Remove the retainer plate, composition brake disc, cam plate and balls.



5. Inspect parts as follows:



a. Composition brake discs are 1/8" thick when new. Replace if thinner than 0.080” 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".

12

RE-ASSEMBLING AND CHECKING THE BRAKE

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

2. Assemble balls into appropriate 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. Refer to Diagram
1 on page 12.



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 on the retainer plate. Tighten capscrews to 7-8 ft. lbs.



9. Bolt cover into place with the mounting screws. Install drain plug and add 1 pint of SAE 140 EP oil.



10. Turn winch in the reel in direction at least one turn of the input shaft.



11. 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 page 11), disengage clutch. Start
vehicle engine and run winch in the reel in direction. Allow winch to run in this direction for one minute.

Place your hand on the brake housing. If housing is not
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 (reel in direction) the brake should be disassembled. When
disassembled, place the brake balls in the alternate set of slots in the cam plate, then carefully follow the
instructions for reassembling and checking the brake.

hot to the touch then run winch in the reverse

13

14



BRAKE ASSEMBLY PARTS LIST

PART NO PART NO QTY DESCRIPTION PART NO PART NO QTY DESCRIPTION

101 306034 1 FLAT SPRING 110 414224 1 CAPSCREW 3/8-16NC X 1 1/2 HEX HD
102 314008 1 CAM PLATE 111 414821 4 CAPSCREW 1/4-20NC X 7/8 BUTTON HD
103 328128 1 BRAKE COVER 112 418036 1 NUT-3/8-16 NC HEX JAM
104 338007 1 BRAKE HOUSING 113 418154 2 WASHER 1/4 FLAT ALUM.
105 340002 1 HUB 114 442189 1 GASKET
106 352022 1 RETAINER PLATE 115 474001 1 THRUST PLATE
107 400003 2 BALL 116 486069 1 THREAD SEAL
108 414021 2 CAPSCREW 1/4NC X 1 LG HEX HD 117 486070 4 THREAD SEAL
109 414039 4 CAPSCREW 1/4-20NC X 1 LG HEX HD 118 494007 1 SPRING

108

113

112

110

15

103

114

115

101

116

102

107

117

109

105

118

104

106

107



111

33

9

28

34

21

35

39

1

41

3

10

16

4

16

16

26

BRAKE ASSEMBLY

7

216

13

27

23

37

38

29

31

24

12

12

SEE PAGE 15 FOR
PARTS BREAKDOWN

15

23

40

14

38

16

6

18

25

30

33

19

36

2

24

15

32

11

17

41

8

22

20

5

32



PARTS LIST

ITEM NO. QTY PART NO. DESCRIPTION ITEM NO. QTY PART NO. DESCRIPTION

1 1 276056 SHIFTER ASSEMBLY 22 2 418218 LOCKWASHER-1/2 MED SECT

2 1 300057 ADAPTER 23 2 438014 BRAKE DISC

3 1 315008 ROPE ANCHOR 24 2 442184 GASKET

4 1 324160 JAW CLUTCH 25 1 442205 GASKET

5 1 324500 COUPLING 26 2 450006 KEY

6 1 328134 GEAR HOUSING COVER 27 4 450016 KEY

7 1 332255 DRUM 28 1 456001 LUBE FITTING

8 1 334179 GEAR 29 1 456008 RELIEF FITTING

9 1 336010 CLUTCH HANDLE 30 1 458050 MOTOR

10 1 338208 CLUTCH HOUSING 31 1 468002 REDUCTER

17

11 1 338273 GEAR HOUSING 32 2 468011 PIPE PLUG

12 3 342027 KEY 33 2 470033 SPIROL PIN

13 1 357488 SHAFT 34 1 472012 PLUG

14 1 368202 WORM 35 1 472013 PLUG

15 2 402002 BALL BEARING 36 1 486009 OIL SEAL

16 4 412003 BUSHING 37 1 486017 OIL SEAL

17 1 412097 BUSHING 38 2 494002 SPRING

18 10 414045 CAPSCREW 1/4-20NC X 7/8 LG HEX HD 39 1 494053 SPRING

19 4 414842 CAPSCREW 1/4-20NC X 1 3/4 LG SOC HD 40 1 518014 THRUST WASHER

20 2 414952 CAPSCREW 1/2-13NC X 1 1/2 LG SOC HD 41 2 518015 THRUST WASHER

21 1 416030 SETSCREW 1/4-20NC X 3/8 HEX SOC



LIMITED WARRANTY

RAMSEY WINCH warrants each new RAMSEY WINCH to be free
from defects in material and workmanship for a period of one (1)
year from date of purchase.

The obligation under this warranty, statutory or otherwise, is
limited to the replacement or repair at the Manufacturer's factory,
or at a point designated by the Manufacturer, of such part that
shall appear to the Manufacturer, 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 connection with the
replacement or repair of defective parts, nor shall it apply to a
product upon which repair or alterations have been made, unless
authorized by Manufacturer, or for equipment misused, neglected
or which has not been installed correctly.

RAMSEY WINCH shall in no event be liable for special or
consequential damages. RAMSEY WINCH makes no warranty 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 through changes in
design or materials as it may deem desirable without being
obligated to incorporate such changes in products 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 that have been incurred by the
Buyer without approval or authorization by RAMSEY WINCH will
not be accepted.

Seewarrantycardfordetails.

RAMSEY WINCH COMPANY

Post Office Box 581510

Tulsa,Oklahoma74158‐1510



Telephone:(918)438‐2760

FAX:(918)438‐6688



OM‐914241‐0909‐A