Ramsey HSW-10000 User Manual

OPERATING SERVICE AND

MAINTENANCE MANUAL

MODEL HSW 10,000

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

WARNINGS 2 WINCH MAINTENANCE 3

CABLE INSTALLATION 4 HYDRAULIC SYSTEMS /

PERFORMANCE CHARTS 4 TYPICAL LAYOUT /

HYD. SYSTEM DIAGRAM 4 TROUBLE SHOOTING GUIDE 5 INSTRUCTIONS FOR OVERHAUL

DIS-ASSEMBLY 6-10 RE-ASSEMBLY 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

BRAKE ASSEMBL Y AND P ARTS LIST 15 EXPLODED VIEW 16 PARTS LIST 17 LIMITED WARRANTY BACK COVER

RAMSEY WINCH MODEL HSW 10,000 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.) ………………………………………………………. 10,000 (Kg) ………………………………………………………… 4,536 Gear ReducƟon …………………………………………………………………… 30:1 Weight (without cable) ……………………………………… 110 lbs. (50 Kg) Duty (Ō.) …………………………………………………………… 183 LAYER OF CABLE 1 2 3 4** * Rated line pull lbs. 10,000 8,100 6,900 4,800 per layer Kg 4,

Ō.

536 3,670 3,120 2,180

125

* Cable Capacity

37 * Line Speed FPM32384454 (at 15 GPM) MPM 9,7 11,5 13,3 16,4

* These speciĮcaƟons are based on recommended wire rope of .44 inch dia. Extra improved plow steel or equivalent.

** Does not conform to SAE J706 speciĮcaƟons.

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

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 clutch is operated by the “T-handle”, located on the end of the winch 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 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 turn ing. 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

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 operat ing condition so that hot oil gasses may escape.

3. Lubricate cable with light oil.

B. MONTHLY

1. Lubricate the various grease ﬁ ttings located in the cable drum, end bearing, clutch hous- ing or clutch operating linkage. Any good grade of moly-disulﬁ de 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. ANNUALL Y

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. Reﬁ ll 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 / HYDRAULIC SYSTEMS

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 ½”” 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.

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 3.6 cubic inches with 15 GPM maximum flow

rate.

HSW-10,000 PERFORMANCE

10,000 LB. DUTY RATING

30:1 GEAR RATIO

WITH 3.6 C.I.D. MOTOR

10,000

9,000

8,000 7,000 6,000 5,000 4,000

3,000

LINE PULL-FIRST LAYER (LB.)

2,000 1,000

DYNAMIC

STATIC

1,000

WORKING PRESSURE, PSI

TYPICAL LAYOUT

CONTROL VALVE EMERGENCY STOP

3 POSITION 4 WAY CYLINDER SPOOL

PUMP INLET LINE

(SUCTION)

PUMP

RELIEF VALVE

FLUID FILTER

FLUID RESERVOIR

LINE SPEED-FIRST LAYER (FPM)

3,0002,000

FLOW (GPM)

HIGH PRESSURE LINES

(.50 I.D. MINIMUM)

WINCH MOTOR

HYDRAULIC

LOW PRESSURE LINES

LOW PRESSURE LINES (.75 I.D. MINIMUM)

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