Ramsey Winch HD 234 RAM-LOK Installation and user guide

OPERATING, SERVICE
AND MAINTENANCE MANUAL
MODEL HD 234 RAM-LOK®
INDUSTRIAL LOW-MOUNT
(MFG. PER JERR-DAN SPECS.)
CAUTION: READ AND UNDERSTAND THIS MANUAL
BEFORE INSTALLATION AND OPERATION OF WINCH.
SEE WARNINGS!

TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
TECHNIQUES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WINCH MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HYDRAULIC SYSTEMS/PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . .6
TYPICAL LAYOUT/HYD. SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . .6
TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
INSTRUCTIONS FOR OVERHAUL OF
RAMSEY MODEL HD-234 RAM-LOK®WINCH
DIS-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
RE-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-18
PARTS LISTS AND PARTS DRAWINGS . . . . . . . . . . . . . . . . . . . . . .20-27
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
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope
manufacturer for wire rope ratings.
Rated Line Pull (lbs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,000
(kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,620
Gear Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34:1
Weight (without cable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110lbs. (50 kg)
LAYER OF CABLE 1234
*Rated line pull lbs. 8,000 6,700 5,700 5,000
per layer kg 3,620 3,030 2,610 2,290
*Cable capacity ft. 25 60 95 140
m 8 18 30 43
*Line speed FPM 28 34 39 44
(at 15 GPM) MPM 8,6 10,1 11,7 13,4
*These specifications are based on recommended wire rope of 3/8 inch diameter extra
improved plow steel or equivalent.
4
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 SETSCREW IS NOT DESIGNED TO HOLD LOAD.
DO NOT USE WINCH AS A TIE DOWN. DO NOT MAINTAIN LOAD ON WINCH CABLE DURING TRAN-
SIT.

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 blan-
ket, jacket or tarpaulin over the cable about
six feet behind the hook. This will slow the
snap back of a broken cable and could pre-
vent serious injury.
NOTE: The Ramsey level winder is an
available accessory for tightly respool-
ing 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 Remote Rod-adapter shifter is oper-
ated as follows:
1. TO DISENGAGE CLUTCH, run the winch
in the reverse (reel out) direction until the
load is off the cable. Lift up knob and
pull out, lock in place. See warning label
located by shifter knob. The clutch is
now locked out and the cable may be
pulled off by hand.
2. TO ENGAGE CLUTCH, lift up knob then
release. See warning label located by
shifter knob. 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 is operated as follows:
1. TO DISENGAGE CLUTCH, run the winch
in the 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 disen-
gage clutch.
2. TO ENGAGE CLUTCH, remove air pres-
sure from air cylinder. Run the winch in
reverse until the cable drum starts turn-
ing. 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 Manual T-Handle Shifter 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 clutch handle snaps fully in or until
the cable drum starts turning. At this
point make sure the clutch handle is all
the way in. To confirm this, remove the
plastic plug on top of the clutch housing
to inspect the clutch for total engage-
ment. After the clutch is fully engaged,
the winch is ready for winching in the
cable.
5

WINCH MAINTENANCE
Adhering to the following maintenance
schedule will keep your winch in top condi-
tion and performing as it should with a mini-
mum 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. 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 exces-
sive wear and replace as neces-
sary.
• 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.
2. Grease the shaft and barth keys the
jaw clutch slides on using Mobilith
SHC 007 Synthetic Grease or equiva-
lent. Replace the plastic plug when
finished.
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. 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 fre-
quently.
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 struc-
ture for cracks or deformation.
5. Gear wear can be estimated by rock-
ing 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, 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 neat-
ly wrapped layers.
6

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
6,000
5,000
4,000
3,000
2,000
1,000
0
LINE PULL - FIRST LAYER (LB.)
0 1,000 2,000 3,000
WORKING PRESSURE, PSI
DYNAMIC
STATIC
0 5 10 15
FLOW, GPM
35
30
25
20
15
10
5
LINE SPEED - FIRST LAYER (FPM)
7

CONDITION
Clutch inoperative or binds up Oil leaks from housing Winch runs too slow Cable birdnests when clutch is disen- gaged Hydraulic fluid leaks out hole in motor adapter
POSSIBLE CAUSE
1. Dry or rusted shaft 2. Bent yoke or linkage. Clutch jaws
are in contact
1. Seal damaged or worn. 2. Too much oil. 3. Damaged gasket. 1. Hydraulic motor worn out. 2. Low flow rate. 1. Drag brake disc worn. 1. Hydraulic motor shaft seal.
CORRECTION
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 7.
1. Replace Discs. 1. Replace damaged seal.
TROUBLESHOOTING GUIDE
8

1. Drain oil from gear housing
by removing (item #36) plug
from bottom of gear housing.
Remove plug (Item #35)
from top of gear housing.
Remove adapter rod (item
#26) by driving pin (item
#37) from shifter shaft of
winch. Remove mounting
frame (item #1) from winch
by removing hardware shown.
2. Remove clutch housing (item #9) and
clutch (item #5) from winch assembly.
Remove two keys (item #31) from key-
ways. A screwdriver can be used, at
notch, to aid in the removal of keys.
Once keys have been removed, drum
(item #7) and thrust washer (item
#46) can be removed from drum shaft.
INSTRUCTIONS FOR OVERHAUL OF RAMSEY
MODEL HD-234 RAM-LOK®
DIS-ASSEMBLY
9

3. Remove motor and coupling (item #27)
from (item #3) adapter by unscrewing
two (item #23) capscrews with lock-
washer.
Remove key (item #11) from worm
shaft. Unscrew four capscrews (item
#19) and remove adapter from gear
housing. Replace adapter seal (item
#41) and gasket (item #29).
4. Remove bearing cap (item #4)
from gear housing by unscrewing
four capscrews (item #18).
Remove worm (item #13) and
bearings (item #14) from gear
housing. Use soft hammer to gen-
tly 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 (item
#13) and bearing (item #14). Replace if neces-
sary.
5. Remove gear housing cover (item #6)
from gear housing (item #10) by
unscrewing capscrews (item #18).
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 (item #30) and pull shaft
(item #12), with gear attached, and thrust wash-
er (item #45) from gear housing.
10

6. Check for signs of wear on gear teeth. If
replacement of gear is necessary, replace as
follows:
a) Press gear (item #8) from shaft (item
#12).
b) Examine shaft keys and keyways. If distor-
tion of keys and/or keyways is evident,
shaft and keys should be replaced.
c) Use a soft hammer to gently tap keys
(item #32) into keyways. Press gear (item
#8) over shaft and keys. Gear must be
centered over keys.
7. Remove seal (item #42) from back of (item
#10) gear housing. Press bushing (item
#16) from gear housing. Press new bushing
and seal back into place.
8. Check drum bushings (item #15) for signs
of wear. Replace if necessary by pressing old
bushings from drum. Press new ones into
place.
9. Examine shifter assembly (item #2) for
damage to yoke. Yoke should be firmly
attached to shaft, yet, able to swivel
freely around shaft. Replace if neces-
sary.
Install new shifter assembly (item #2)
by placing end of shaft, opposite yoke,
through spring (item #44) and into
housing (item #9).
11

9a.For the air shifter, examine yoke (item
#14 for damage. Yoke should be firmly
attached to shaft. Replace if necessary.
If air cylinder (item #30) needs to be
replaced, remove it from the end of the
clutch housing by removing 4 cap-
screws (item #25) and lockwashers
(item #27). Inspect the breather vent
(item #38) and elbow connector (item
#29) to ensure they are not plugged.
10.Check cover bushing (item #15) for
signs of wear. If necessary remove old
bushing and press bushing into place.
11.Apply grease to end of shaft, oppo-
site gear. Apply grease to bushing in
gear housing (item #10). Place
greased end of shaft through thrust
washer (item #46) and bushing in
gear housing (item #10). Place gas-
ket (item #30) onto gear housing
cover (item #6). Apply grease to
gear end of shaft and cover bushing.
Place cover onto shaft and secure to
housing with ten (item #18) cap-
screws. Tighten capscrews to 8 ft.
lbs. (10.8 Nm.) each.
RE-ASSEMBLY
12
10
26
47
14
30
29
38
25
41
36
45
16
27

12.Press bearing (item #14) onto
worm (item #13). NOTE: Be sure
that thick shoulder of bearings
outer race (side with manufactur-
er's name and part number) is
out, away from worm threads.
Press bearing and worm into gear
housing. Slip gasket (item #29)
onto bearing cap (item #4). Use
four capscrews (item #18) to secure cap to gear
housing. TIGHTEN CAPSCREWS TO 8 FT.
LBS. (10.8 Nm.) EACH.
13.Press bearing (item #14) 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 gas-
ket (item #29) onto adapter (item #3).
Attach adapter to gear housing using four
(4) capscrews (item #22). TIGHTEN
CAPSCREWS TO 12 FT. LBS. (16.3 Nm.)
EACH. Insert key (item #11) into keyway
of worm shaft. Slide tapered end of cou-
pling (item #27) over end of worm shaft.
Be sure roll pin (item #38) is in coupling.
Place motor shaft, with key in keyway, into cou-
pling. Secure motor to adapter, using two (2)
capscrews (item #23) and lockwashers.
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 (item #45) over
drum shaft and slide downward until washer
rests on gear housing. Set springs (item #43)
into pockets of gear housing with drag brakes
(item #28) on top of springs. Slide drum
assembly (item #7) onto drum shaft with
drum jaws upward.
13

15.Place thrust washer (item #46) over end
of drum shaft and slide downward until
spacer rests on drum. Press drum down-
ward to compress springs in gear housing.
Insert keys (item #31) 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 Mobilith SHC 007 Synthetic grease
to keys and end of shaft. place jaw clutch
(item #5) over end of shaft and slide jaw
clutch over keys.
Set clutch housing (item #9) over end of
drum shaft. Pull jaw clutch (item #5)
upward, toward clutch housing, enough to
allow yoke, in clutch housing, to fit proper-
ly in groove around jaw clutch.
16.Attach frame assembly (item
#1) using six capscrews (item
#21) with lockwashers and
two capscrews (item #20)
with lockwasher. Torque cap-
screws to 34 ft. lbs. (46 Nm.)
each. Insert plug (item #36)
into bottom of gear housing.
Permatex may be applied to
threads to help prevent leakage.
Attach adapter rod (item #26)
to clutch shaft using pin (item
#37).
Pour 3/4 pint of Phillips SMP 80W-90,
Mobil HD 80W-90, Shell Spirax HD
80W-90 or CITGO MP 80W-90 gear oil
only into housing through hole in top of
housing. Pipe plug (Item #35) should then
be placed into hole on top of gear housing.
Tighten securely.
14

29.75
19.56
2.50 13.12 2.50 5.81
7.78
.78
1.91
7.25 DIA.
3.50 DIA.
11.94
1.12
.31
6.21
3.71 3.63
2.12
12.44
(REF.)
6.87 3.33
5.13
4.00
Model HD-234 Ram-Lok®Remote Shifter Adapter
15

3.33
1.72
.78
1.89
2.50 5.81
2.00
2.12
4.51
9.00
6.87
3.12
6.21
12.44
.88
2.50
Ø7.25
FLANGE
19.56
29.75
7.78
Ø3.50
DRUM
11.31
1.13
13.12
Ø.44 CABLE ANCHOR
FOR Ø3/8 WIRE ROPE
1.56
3.91
COMPRESSION FITTING
FOR 1/4 O.D. TUBING
(60 PSI MIN.)(125 PSI MAX.)
FOR DISENGAGING CLUTCH,
(CLUTCH IS SPRING ENGAGED)
DETAIL A-A
10°
(REF)
COMPRESSION FITTING FOR
AIR CYLINDER TO BE
ORIENTED AS SHOWN
16
Model HD-234 Air Shifter down

4.00
5.13
3.336.87
(REF)
12.44
2.12
3.63 3.71
6.21
.31
1.12
11.94
3.50 DIA.
7.25 DIA.
1.91
.78
7.78
5.812.5013.122.50
19.56
29.75
COMPRESSION FITTING FOR 1/4 O.D. TUBING.
(60 PSI MINIMUM)(125 PSI MAXIMUM)
FOR DISENGAGING CLUTCH.
(CLUTCH IS SPRING ENGAGED)
3.56
Model HD-234 Air Shifter up
17

Model HD-234 Ram-Lok®T-handle Manual Shifter
29.75
5.81
2.12
1.25
POSITION
CLUTCH AT
DIS-ENGAGED
CLUTCH AT
POSITION
ENGAGED
4.00
3.336.87
(REF.)
12.44
2.12
3.63 3.71
6.21
.31
1.12
11.94
3.50 DIA.
7.25 DIA.
1.91
.78
7.78
2.5013.122.50
19.56
18

20