OPERATING, SERVICEAND MAINTENANCE

MANUAL

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFOREINSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!

MODEL HD-234 AIR SHIFT

INDUSTRIAL LOW-MOUNT WINCHES

TABLE OF CONTENTS

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

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

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

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

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

WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

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

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

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

INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL HD-234 WINCH

DIS-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9RE-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

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

PARTS LIST AND PARTS DRAWING . . . . . . . . . . . . . . . . . . . . . . . . .15-16

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BACK COVER

RAMSEY WINCH MODEL HD-234

PLEASE READ THIS MANUAL CAREFULLY.

This manual contains useful ideas in obtaining the most efficient operation from yourRamsey Winch, and safety procedures one needs to know before operating aRamsey Winch.

WARRANTY INFORMATION

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

SPECIFICATIONS: CONFORMS TO SAE J706*

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

LAYER OF CABLE 1 2 3 4

*Rated line pull lbs. 8,000 6,700 5,700 5,000per layer kg 3,620 3,030 2,610 2,290

**Long Drum ft. 25 60 95 140Cable capacity m 8 18 30 43

**Line speed FPM 28 34 39 44MPM 8,6 10,1 11,7 13,4

* Winch only conforms to SAE J706. For SAE qualification of mounting angles, if applicable, consultRamsey Engineering** These specifications are based on recommended wire rope of 3/8 inch diameter extra improved plowsteel or equivalent.

Rated Line Pull (lbs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,000(kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,620

Gear Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34:1Weight HD-234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110lbs. (50 kg)

1

TECHNIQUES OF OPERATIONThe best way to get acquainted with how your winch operates is to make test runs beforeyou actually use it. Plan your test in advance. Remember, you hear your winch, as well assee it operate. Get to recognize the sounds of a light steady pull, a heavy pull, and soundscaused by load jerking or shifting. Gain confidence in operating your winch and its use willbecome second nature with you.

The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cablepileup on one end of drum. If this happens reverse the winch to relieve the load and moveyour anchor point further to the center of the vehicle. After the job is done you can unspooland 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 backof a broken cable and could prevent serious injury.

NOTE: The Ramsey level winder is an available accessory for tightly respoolingunloaded cable onto the drum.

The winch clutch allows rapid unspooling of the cable, from cable drum, for holding onto aload. The clutch is operated by the lever located on the clutch housing of winch.

1. TO DISENGAGE CLUTCH, run the winch in the reverse (reel out) direction until the load isoff the cable. Apply 60-125 PSI to inlet port fitting of air cylinder.

2. TO ENGAGE CLUTCH, remove air pressure from air cylinder. Run the winch in reverseuntil the cable drum starts turning. The plastic plug in top of clutch housing may beremoved for inspection of clutch to assure total engagement. After the clutch is fullyengaged, 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.

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 TOHOLD THE LOAD. CABLE SETSCREW IS NOT DESIGNED TO HOLD LOAD.

2

3

WINCH MAINTENANCEAdhering to the following maintenance sched-ule will keep your winch in top condition andperforming as it should with a minimum ofrepair.A. WEEKLY1. Check the oil level and maintain it to the oil

level plug. If oil is leaking out, determinelocation and repair.

2. Check the pressure relief plug in top of thegear housing. Be sure that it is in goodoperating condition so that hot oil gasesmay escape.

3. Lubricate cable with light oil.B. MONTHLY1. Lubricate the various grease fittings located

in the cable drum, end bearing, clutchhousing, or clutch operating linkage. Anygood grade of moly-disulfide containinggrease is acceptable.

2. Check the action of the sliding clutch—ensure it is fully engaging and disengagingwith the cable drum. To observe if theclutch is fully engaging, remove the plasticplug in top of the housing. If clutch is notfully engaging:• Inspect clutch shifter assembly parts,

check for damage or excessive wearand replace as necessary.

• Observe the jaws on both the clutchand cable drum, checking for roundingof the driving faces. If rounding hasoccurred they should be replacedimmediately.

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

4. Check alignment of chain and sprocketsand adjust as required to minimize wear.

5. Inspect the cable. If the cable has becomefrayed with broken strands, replace imme-diately.

C. ANNUALLY1. 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 minuteswith no load in the reel in direction. Drainthe kerosene from the winch.

3. Refill the winch to the oil level plugwith Phillips SMP 80W-90, Mobil HD80W-90, Shell Spirax HD 80W-90, orCITGO MP 80W-90 gear oil only.

4. Inspect frame and surrounding structurefor cracks or deformation.

5. Gear wear can be estimated by rocking thedrum back and forth and if necessary drainoil and remove cover for closer inspection.

WINCH MOUNTINGIt is most important that this winch bemounted securely so that the three majorsections (clutch housing end, cable drum,and gear housing end) are properly aligned.All standard model HD-234 series winchesare furnished with recommended mountingangles. Angle size is 1/4 x 2-1/2 x 2-1/2 x36” long high strength steel angle.

CABLE INSTALLATION1. Unwind cable by rolling it out along the

ground to prevent kinking. Securely wrapend of cable, opposite hook, with plasticor similar tape to prevent fraying.

2. Insert the end of cable, opposite hookend, into the 7/16" dia. hole in drum bar-rel. Secure cable to drum barrel, usingsetscrew furnished with winch. TIGHTENSETSCREW SECURELY.

3. Carefully run winch in the "reel-in" direc-tion. Keeping tension on end of cable,spool all the cable onto the cable drum,taking care to form neatly wrapped lay-ers.

HYDRAULIC SYSTEMS

Refer to performance charts, below, to properly match your hydraulic system tothe HD-234 winch performance. The charts consist of:

1. Line pull (lbs.) first layer vs. working pressure (PSI). STATIC (solid line) refersto hoisting a suspended load from rest; DYNAMIC (dashed line) refers tomaintaining 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 15GPM maximum flow rate.

HD-234 PERFORMANCE8,000 LB. DUTY RATING - 34:1 GEAR RATIO

WORKING PRESSURE, PSI

FIR

ST

LAY

ER

LIN

E P

ULL

, LB

S

3,000

2,000

1,000

0

5,000

4,000

7,000

6,000

8,000

DYN

AM

IC

20001000

STA

TIC

3000

FLOW, GPM

LIN

E S

PE

ED

, FP

MFI

RS

T LA

YE

R

00

5

5

10

15

20

10 15

25

30

35

4

5

CONDITION POSSIBLE CAUSE CORRECTION

1. Dry or rusted shaft. 1. Clean and lubricate

2. Clutch jaws are in contact. 2. See Techniques of Operation .

1. Seal damaged or worn. 1. Replace seal.

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

3. Damaged gasket. 3. Replace gasket.

1. Hydraulic motor worn out. 1. Replace motor.

2. Low flow rate.2. Check flow rate. Refer to Hydraulic Systems flow chart.

CABLE BIRDNESTS WHEN CLUTCH IS DISENGAGED

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

HYDRAULIC FLUID LEAKS OUT HOLE IN MOTOR ADAPTER

1. Hydraulic motor shaft seal damaged.

1. Replace seal.

CLUTCH INOPERATIVE OR BINDS UP

OIL LEAKS FROM HOUSING

WINCH RUNS TOO SLOW

Troubleshooting Guide

1. Drain oil from gear housing by removingplug (item #33) from bottom of gearhousing. Remove plug (items #32) fromtop of gear housing.

2. Remove clutch housing (item #8) and clutch(item #3) from winch assembly.

3. Remove two keys (item #27) from keyways. Ascrewdriver can be used, at notch, to aid in theremoval of keys. Once keys have been removed,drum (item #5) and thrust washer (item #42)can be removed from drum shaft.

INSTRUCTIONS FOR OVERHAUL OF RAMSEYMODEL HD-234

DIS-ASSEMBLY

6

4. Remove coupling (item #21) from adapter(item #1) by unscrewing four screws (item#16).Replace adapter seal (item #36) and gas-ket (item #25).

5. Remove bearing cap (item #2) from gear housing by unscrewing four capscrews(item #15). Remove worm (item #10) and bearings (item #12) from gear hous-ing. Use soft hammer to gently tap input end of worm and drive worm and bear-ing from gear housing. Once worm has been removed from housing, bearing canbe pressed from end of worm.Check for signs of wear or damage to worm (item #10) and bearing (item #12).Replace if necessary.Drag brake disc (item #24) and spring (item #39) should be examined andreplaced if necessary.

7

6. Remove gear housing cover (item#4) from gear housing (item #7) byunscrewing capscrews (item #15).Thread two of the capscrews into thetwo tapped holes of cover and tight-en. This will pull the cover loosefrom the gear housing.

Remove cover gasket (item #26)and pull shaft (item #9), with gearattached, and thrust washer (item#42) from gear housing.

7. Check for signs of wear on gear teeth. Ifreplacement of gear is necessary, replace asfollows:

a) Press gear (item #6) from shaft (item #9).

b) Examine shaft keys and keyways. If distor-tion of keys and/or keyways is evident, shaftand keys should be replaced.

c) Use a soft hammer to gently tap keys (item#28) into keyways. Press gear (item #6)over shaft and keys. Gear must be cen-tered over keys.

8. Remove seal (item #37) from back ofgear housing (item #7). Press bushing(item #14) from gear housing. Press newbushing and seal back into place.

9. Check drum bushings (item #13) forsigns of wear. Replace if necessaryby pressing old bushings from drum.Press new ones into place.

8

10.Examine yoke (item #11) for damage.Yoke should be firmly attached to shaft.Replace if necessary. If air cylinder(item #23) needs to be replaced,remove it from the end of the clutchhousing by removing 4 capscrews (item#18) and lockwashers (item #20).Inspect the breather vent (item #31)and elbow fitting (item #22) to ensurethey are not plugged.

11.Check cover bushing (item #14) forsigns of wear. If necessary remove oldbushing and press new bushing intoplace.

12.Apply grease to end of shaft, opposite gear. Apply grease to bushing in gearhousing (item #7). Place greased end of shaft through thrust washer (item#42) and bushing in gear housing (item #7). Place gasket (item #26) ontogear housing cover (item #4). Apply grease to gear end of shaft and coverbearing. Place cover onto shaftand secure to housing with tencapscrews (item #15). Tightencapscrews to 8 ft-lbs. (10.8Nm) each.

RE-ASSEMBLY

9

13.Press bearing (item #12) onto worm (item #10) Note: Be sure that thickshoulder of bearing’s outer race (side with manufacturer’s name and partnumber) is out, away from worm threads. Press bearing and worm into gearhousing. Slip gasket (item #25) onto bearing cap (item #2). Use four cap-screws (item #15) to secure cap to gear housing. Tighten capscrews to 8ft-lbs. (10.8 Nm) each.

10

14.Press bearing (item #12) onto worm and into gear housing. Note: Be surethat thick shoulder of bearing’s outer race (side with manufacturer’s nameand part number) is out, away from worm threads.

15.Place gasket (item #25) onto adapter (item #1). Slide seal (item #36) ontoworm. Slide tapered end of coupling (item #21) over end of worm shaft.Attach adapter and coupling to gear housing using four screws (item #16).Tighten screws to 12 ft-lbs. (16.3 Nm) each.

16.Place winch with gear housing cover downon work bench. Drum shaft should be in ver-tical position. Slide thrust washer (item#42) over drum shaft and slide downwarduntil washer rests on gear housing. Setsprings (item #39) into pockets of gearhousing with drag brakes (item #24) on topof springs. Slide drum assembly (item #5)onto drum shaft with drum jaws upward.

11

17.Place thrust washer (item #42) over end of drum shaft and slide down-ward until space rests on drum. Press drum downward to compresssprings in gear housing.

Insert keys (item #27) into keyways withsharp edge of keys pointing outward andnotched end of keys upward. A rubber orbrass mallet will be needed to gently tapkeys into position.

Apply grease to keys and end of shaft.Place jaw clutch (item #3) over end ofshaft and slide jaw clutch over keys.

Set clutch housing (item #8) over end ofdrum shaft. Pull jaw clutch (item #3)upward, toward clutch housing, enough toallow yoke, in clutch housing, to fit proper-ly in groove around jaw clutch.

18.Insert plug (item #33) into bottom of gear housing. Permatex may beapplied to threads to help prevent leakage.

Pour 3/4 pint of Phillips SMP 80W-90, Mobil HD 80W-90, ShellSpirax HD 80W-90, or CITGO MP 80W-90 gear oil only into housingthrough hole in top of hous-ing. Plug (item #32)should then be placed intohole on top of gear hous-ing. Tighten reducersecurely.

12

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16

LIMITED WARRANTY

RAMSEY WINCH warrants each new RAMSEY winch to be free from defectsin material and workmanship for a period of one (1) year from date of pur-chase.

The obligation under this warranty, statutory or otherwise, is limited to thereplacement or repair at the Manufacturer's factory, or at a point designatedby the Manufacturer, of such part that shall appear to the Manufacturer,upon inspection of such part, to have been defective in material or work-manship.

This warranty does not obligate RAMSEY WINCH to bear the cost of laboror transportation charges in connection with the replacement or repair ofdefective parts, nor shall it apply to a product upon which repair or alter-ations have been made, unless authorized by Manufacturer, or for equip-ment misused, neglected or which has not been installed correctly.

RAMSEY WINCH shall in no event be liable for special or consequentialdamages. RAMSEY WINCH makes no warranty in respect to accessoriessuch as being subject to the warranties of their respective manufacturers.

RAMSEY WINCH, whose policy is one of continuous improvement, reservesthe right to improve its products through changes in design or materials asit may deem desirable without being obligated to incorporate such changesin products of prior manufacture.

If field service at the request of the Buyer is rendered and the fault is foundnot to be with RAMSEY WINCH's product, the Buyer shall pay the time andexpense to the field representative. Bills for service, labor or other expensesthat have been incurred by the Buyer without approval or authorization byRAMSEY WINCH will not be accepted

See warranty card for details.

OM-914172-0705-A

RAMSEY WINCH COMPANY P.O. Box 581510 • Tulsa, Oklahoma 74158-1510 USA

Phone: (918) 438-2760 • Fax: (918) 438-6688www.ramsey.com