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.
TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 TECHNIQUES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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. 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.
4. Inspect the cable. If the cable has become frayed with broken strands, replace immediately. 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. 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.
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.
1. Drag brake disc worn. 1. Hydraulic motor shaft seal. Cable birdnests when clutch is disengaged Hydraulic fluid leaks out hole in motor adapter 1. Replace damaged seal. 1. Replace Discs. 1. Replace motor. 2. Check flow rate. Refer to Hydraulic Systems flow chart page 7. Oil leaks from housing 1. Hydraulic motor worn out. 2. Low flow rate. 1. Replace seal. 2. Drain excess oil. Refer to Techniques of Operation. 3. Replace gasket. 1. Seal damaged or worn. 2. Too much oil. 3. Damaged gasket.
INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL HD-234 RAM-LOK® DIS-ASSEMBLY 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 keyways.
3. Remove motor and coupling (item #27) from (item #3) adapter by unscrewing two (item #23) capscrews with lockwasher. 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.
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 distortion 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.
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 capscrews (item #25) and lockwashers (item #27). Inspect the breather vent (item #38) and elbow connector (item #29) to ensure they are not plugged. 27 10 25 30 45 16 38 29 36 41 47 14 10.Check cover bushing (item #15) for signs of wear.
12.Press bearing (item #14) onto worm (item #13). 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 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.
15.Place thrust washer (item #46) over end of drum shaft and slide downward until spacer rests on drum. Press drum downward 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.
5.13 .31 2.50 11.94 3.50 DIA. 29.75 13.12 7.25 DIA. 19.56 7.78 2.50 .78 Model HD-234 Ram-Lok® Remote Shifter Adapter 15 1.91 1.12 5.81 4.00 2.12 3.63 3.71 6.87 6.21 12.44 (REF.) 3.
3.91 1.56 10° (REF) 1.13 DETAIL A-A .88 Ø7.25 FLANGE Ø.44 CABLE ANCHOR FOR Ø3/8 WIRE ROPE 11.31 13.12 19.56 29.75 COMPRESSION FITTING FOR AIR CYLINDER TO BE ORIENTED AS SHOWN COMPRESSION FITTING FOR 1/4 O.D. TUBING (60 PSI MIN.)(125 PSI MAX.) FOR DISENGAGING CLUTCH, (CLUTCH IS SPRING ENGAGED) 2.50 Model HD-234 Air Shifter down 16 Ø3.50 DRUM 7.78 2.50 .78 5.81 2.00 1.89 2.12 4.51 3.12 6.87 6.21 12.44 9.00 3.33 1.
COMPRESSION FITTING FOR 1/4 O.D. TUBING. (60 PSI MINIMUM)(125 PSI MAXIMUM) FOR DISENGAGING CLUTCH. (CLUTCH IS SPRING ENGAGED) 3.56 5.13 .31 2.50 Model HD-234 Air Shifter up 17 13.12 11.94 7.25 DIA. 19.56 3.50 DIA. 29.75 7.78 2.50 .78 1.91 1.12 5.81 4.00 2.12 3.63 3.71 6.87 6.21 12.44 (REF) 3.
.31 2.50 13.12 11.94 7.25 DIA. 19.56 3.50 DIA. 29.75 7.78 2.50 .78 1.91 1.12 5.81 Model HD-234 Ram-Lok® T-handle Manual Shifter CLUTCH AT DIS-ENGAGED POSITION 2.12 CLUTCH AT ENGAGED POSITION 1.25 4.00 2.12 3.63 3.71 6.87 6.21 12.44 (REF.) 3.
QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 4 1 14 2 6 4 2 1 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 414277 414282 414842 414952 416059 242174 276057 300057 316083 324502 328152 332150 334183 296633 338273 342027 357479 368203 402002 412003 412045 413013 414045 PART NO. SETSCREW 3/8-16NCX1/2 LG. SOC. HD CAPSCREW 3/8-16NC X 1 LG HX HD GR.5 CAPSCREW 3/8=16NCX1-1/4 LG. SOC. HD. GR.5 CAPSCREW 1/4-20NCX1-3/4LG. SOC. HD. L/W CAPSCREW 1/2-13NCX1-1/2 LG. SOC. HD.
242174 276059 296640 300057 316083 324502 328152 332150 334183 336010 338273 342027 357479 368203 402002 412003 412045 413013 414045 414277 414282 414842 414952 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 4 1 14 2 6 4 2 PART NO. ITEM QTY. FRAME ASSEMBLY SHIFTER ASSEMBLY HOUSING - CLUTCH ADAPTER BEARING CAP JAW CLUTCH COVER DRUM - “STD” GEAR R.H. - 34:1 HANDLE HOUSING - GEAR KEY SHAFT - DRUM “STD.” WORM R.H.
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 14 2 6 4 2 1 4 Parts No. 242176 299037 300057 316083 324502 328152 332150 334183 338273 296632 342027 357479 368203 370043 402002 412003 412045 413013 414045 414279 414282 414842 414952 416059 416198 Qty. 1 4 8 1 1 2 2 1 2 4 1 1 3 1 1 1 1 1 2 1 1 2 Item No.
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 14 2 6 4 2 Parts No. 242174 296644 299037 300057 316083 324502 328152 332150 334183 338273 342027 357479 368203 370043 402002 412003 412045 413013 414045 414277 414282 414842 414952 Item No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Qty. 1 4 1 4 8 1 1 2 2 1 2 4 1 1 3 1 1 1 1 2 1 1 2 Parts No.
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.
