MODEL H 700 DOW-LOK EQUIPPED INDUSTRIAL LOW-MOUNT WINCHES (WITH 20,000 LB RATING)

Transcription

1 Ramsey Winch Company OPERATING, SERVICE AND MAINTENANCE MANUAL MODEL H 700 DOW-LOK EQUIPPED INDUSTRIAL LOW-MOUNT WINCHES (WITH 20,000 LB RATING) CAUTION: Read and understand this manual before installation and operation of winch. See Safety Precautions.

2 Table of Contents Warranty Information 1 Specifications 1 Techniques of Operation 2 Warnings 2 Winch Maintenance 3 Winch Mounting 4 Cable Installation 4 Hydraulic System Requirements 5 Performance Charts 5 Typical Hydraulic Layout 5 Trouble Shooting Guide 6 Instructions for Overhaul 7-12 Dimensional Drawings 13 Parts List and Parts Drawing Notes Warranty 18

3 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. Do not operate this winch until you have carefully read and understand the WARNINGS and OPERATION sections of this manual. 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 back to Ramsey Winch Company. If you have any problems with our winch, please follow instructions for prompt service on all warranty claims. Refer to back page of this manual for limited warranty. SPECIFICATIONS Rated Line Pull (lbs.) 20,000 (kg) 9,070 Gear Reduction 35:1 Shipping Weight: 258 LB Layer of Cable ** *Rated line pull per layer (lbs.) 20,000 16,500 14,000 12,200 10,800 (kg) 9,070 7,480 6,350 5,530 4,890 *Cable Capacity (ft)* (m)* *Line speed H 700 FPM (575 Worm 30 GPM) MPM 6,7 7,9 9,4 10,6 12,1 * These specifications are based on recommended wire rope of.56 inch (15mm) diameter 6x19 extra improved plow steel cable Note: The rated line pulls shown are for the winch only. Consult wire rope manufacturer for wire rope ratings. ** Fifth layer does not conform to SAE J706 1

4 TECHNIQUES OF OPERATION The best way to get acquainted with how your winch 1 operates is to make test runs before you actually use it. Plan your test in advance. Remember to listen to your winch, as well as to watch how it operates. Get familiar with 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 to you. The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pile-up on one end of the drum. If this happens, reverse the winch to relieve the load and move your anchor point further toward the center of the vehicle. After the job is done, you can unspool and rewind for a neat lay of the cable. The Dow-lok clutch provides freespooling and clutch engagement with the cable drum. With the clutch disengaged, the cable can be freespooled off the drum. For winching the load, the clutch must be fully engaged with the drum. Notches on the shifter shaft engage the bracket to positively latch the Dow-lok clutch in the engaged, IN position or the disengaged, OUT position. TO DISENGAGE CLUTCH raise handle so notch clears bracket. Push handle in and latch the shaft notch onto bracket. TO ENGAGE CLUTCH raise handle so notch clears bracket. Pull handle out as far as it will go. The clutch will automatically spring into engagement and latch when the clutch aligns with the drum shaft. In order to attain full engagement, internal elements of the clutch MUST be aligned. This alignment will take place when cable drum or cable shaft turns a maximum of ¼ revolution. DO NOT ATTEMPT TO LIFT A LOAD UNLESS NOTCH IN SHIFTER SHAFT IS SECURELY LATCHED. KEEP CLEAR OF SPRING LOADED HANDLE DURING AUTOMATIC ENGAGEMENT. 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 USE. STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS. STAND CLEAR OF CABLE WHEN 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 ANCHOR IS NOT DESIGNED TO HOLD LOAD. 2

5 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. WEEKLY 1. Check the oil level and maintain it to the oil plug level. If oil is leaking out, determine location and repair. 2. Check the pressure relief plug in top of gear housing. Be sure that it is in good operating condition so that hot oil gasses may escape. 3. Lubricate cable with light oil. MONTHLY 1. Lubricate the various grease fittings located in the drum cable, end bearing, clutch housing or operating linkage. Any good grade of moly-disulfide containing grease is acceptable. 2. Check the action of the locking ring. Make sure it is spring loaded and free to move fully against the cable drum in the engaged position and that it is pulled fully away from the cable drum and latched when disengaged. 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. Check alignment of chain and sprockets and adjust as required to minimize wear. 5. Inspect the cable. If the cable has become frayed with broken strands, replace immediately. ANNUALLY 1. Drain the oil from the winch annually or more often if the 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 direction. Drain the kerosene from the winch. 3. Refill the winch to the oil plug level 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. 3

6 WINCH MOUNTING It is most important that this winch be mounted securely so that the three major sections (the clutch housing end, the cable drum, and the gear housing end) are properly aligned. All standard model H 700 series winches are furnished with recommended mounting angles. Angle size is ½ x 3 x 3 high strength steel angle. CABLE INSTALLATION The H 700 Dow-lok winch has 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 underwound 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 wire rope opposite hook, with plastic or similar tape to prevent fraying. 2. Slide the wire rope through narrow end of the pocket against drum flange and wrap the wire rope around the anchor puck and pull the wire rope and anchor back into the wide end of the pocket. Use a soft hammer to drive the back side of the wire rope, firmly seating the rope and anchor into the pocket. 3. Carefully run the winch in the reel in direction. Keeping tension on the end of the cable, spool all the cable onto the cable drum, taking care to form neatly wrapped layers. 4

7 HYDRAULIC SYSTEM REQUIREMENTS Refer to the performance charts below to properly match your system to H 700 Dow-lok performance. The charts consist of: winch 1. Line pull (lb) first layer vs. working pressure (PSI). Static (solid line) refers to hoisting a suspended load from rest; Dynamic (dotted 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 11.9 cubic inches with 30 GPM maximum flow rate. See page 13 for motor port size. PERFORMANCE CHARTS TYPICAL LAYOUT DUAL-A & B PORT CONTROL HIGH PRESSURE LINE (.75 I.D. MINIMUM) A PUMP PUMP INLET LINE (SUCTION) MOTOR B CONTROL VALVE 3 POSITION 4 WAY VALVE (MOTOR SPOOL OR CYLINDER SPOOL) FLUID RESERVOIR LOW PRESSURE LINE (1.13 I.D. MINIMUM) 5

8 TROUBLESHOOTING GUIDE CONDITIONS POSSIBLE CAUSE CORRECTION CLUTCH INOPERATIVE OR BINDS UP 1. Dry or rusted shaft. 1. Clean and Lubricate. 2. Bent yoke or linkage 2. Replace yoke or shaft assembly. CLUTCH HANDLE WON T LATCH 1. Debris in clutch. 1. Clean and lube per page 11. OIL LEAKS FROM HOUSING 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. LOAD DRIFTS DOWN 1. Counterbalance valve not functioning properly. 1. Replace Counterbalance valve. WINCH RUNS TOO SLOW 1. Hydraulic motor worn out. 1. Replace motor. 2. Low flow rate. 2. Check flow rate. Refer to Hydraulic Systems flow chart, page 5. CABLE DRUM WILL NOT FREESPOOL 1. Winch not mounted squarely, causing end bearings to bind 1. Check mounting. Refer to Winch Mounting, page 4. CABLE BIRDNESTS WHEN CLUTCH IS DISENGAGED 1. Drag brake disc worn. 1. Replace discs. HYDRAULIC FLUID LEAKS FROM HOLE IN ADAPTER 1. Damaged motor shaft seal. 1. Replace seal. 6

9 INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL H 700 DOW-LOK DIS-ASSEMBLY Refer to parts list and parts drawing pages for actual item numbers and corresponding parts numbers. 4 4 (1) Drain oil from gear housing by removing pipe plug (item #54) from gear housing. Shift clutch into the engaged "IN" position. Remove frame angles (item #4) from winch assembly (2) Remove two capscrews (item #32) from clutch housing (item #15) and unlatch shifter assembly. Remove clutch housing from end of drum shaft. Press in on retainer plate (item #59), to relieve the spring tension and remove the retainer ring (item #61). Remove four capscrews (item #30), retainer plate (item #59), springs (item #63) and spacer (item #21). (3) Slide the locking ring (item #9) from the clutch. NOTE: The locking ring cannot be removed unless the clutch is engaged, with dowel pins (item #55) seated in the shaft keyways. Rotate the drum so the eight balls (item #24) and four dowel pins (item #55) can be removed. If necessary, the clutch (item #8) may be disassembled from the drum by removing eight capscrews (item #34). Slide drum (item #12) from drum shaft. Retain springs (item 62), drag brake shoes (item 11), and brake spacers (item # 67) for re-assembly

10 (4) Remove counterbalance valve (item #65) from motor (item #51) by removing (3) capscrews (item #39). Remove motor from adapter plate (item # 20) by removing capscrews (item #40). Remove adapter plate and coupling (item #2) from adapter (item #3) by unscrewing (6) capscrews (item #38). Remove key (item #16) from worm shaft. Unscrew (6) capscrews (item #38) and remove adapter from gear housing. Replace adapter seal (item #25) and gasket (item # 47) (5) Remove worm cap (item #7) by removing (6) capscrews (item #36).Remove worm (item #22) and bearings (item #25) from gear housing. Use a soft hammer to gently tap input end of worm driving 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 # 22) and bearings (item #25). Replace if necessary. 25 (6) 14 Remove gear housing cover (item #10) from gear housing (item #14) by removing (8) capscrews (item # 33). Thread (2) of the capscrews into the (2) tapped holes of cover and tighten. This will pull the cover loose from the gear housing Remove cover gasket (not shown) and pull shaft (item #18) with gear (item #13) and spacer (item #52) from gear housing

11 (7) Check for signs of wear on gear teeth. If necessary replace gear. (8) If shaft or gear is damaged, replace as follows: a. Tap keys (item #17) into short keyways of drum shaft. b. Press shaft (item #18) and keys through gear (item #13) until end of keys on long end of shaft are flush with hub. 14 (9) Check gear housing bushing (item #5) and o-ring (item #52) for signs of wear. Replace if necessary by pressing old bushings from gear housing (item #14). Press new bushing into place and insert new o-ring (item #52) into groove inside of bushings (10) Check drum bushings (items 27 & 28) for signs of wear. Replace if necessary by pressing old bushings from drum (item #12). Press bushing (item #27) into bore in drum until the flange is seated against bottom of counterbore. Press bushing (item # 28) into opposite bore on drum until end of bushing extends.50 from end of drum. 9

12 (11) Check end bearing bushing (item # 28) for signs of wear. If necessary remove old bushing and press new bushing into place (12) Check cover bushing (item #5) and o-ring (item #52) for signs of wear. Replace if necessary by pressing old bushing from gear housing cover (item #10). Press new bushing into place and insert new o-ring (item # 52) into groove inside of bushing. RE-ASSEMBLY (13) Slide spacer (item # 52) over long end of shaft and place against gear hub. Apply grease to end of shaft opposite gear. Apply grease to bushing in gear housing (item # 14). Place greased end of shaft through bushing in gear housing (item #14). Place gasket (not shown) onto gear housing cover (item #10). Apply grease to gear end of shaft and cover bushing. Place cover onto shaft and secure to housing with (8) capscrews (item #33). Tighten capscrews to 39 ft lb (52 Nm) each (14) Place bearing (item #25) onto worm (item #22). Note: Be sure that thick shoulder of bearing s 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 #47) onto worm cap (item #7). Use (6) capscrews (item # 36) to secure worm to gear housing. Tighten capscrews to 45 ft lb (61 Nm) each

13 (15) Attach adapter (item #3) to gear housing using (6) capscrews (item #38). Tighten capscrews to 45 ft lb (61 Nm) each. Insert key (item # 16) into keyway of worm shaft. Slide coupling (item #2) over end of worm shaft. Attach adapter plate (item #20) to adapter using (6) capscrews (item # 38). Tighten capscrews to 45 ft lb (61 Nm) each Place motor shaft, with key in keyway, into coupling. Secure motor (item #51) to adapter using (2) capscrews (item #40). Tighten capscrews to 102 ft lb (138 Nm) each. Attach counterbalance valve (item #65) with (3) capscrews (item #39). 12 (16) Place winch with gear housing cover down on workbench. Drum shaft should be in vertical position. Set springs (item # 62) into pockets of gear housing with drag brakes (item #11) on top of disc (item #67) and springs. Slide drum assembly (item #12) onto drum as shown (17) Place clutch (item #8) over end of drum shaft. Align the clutch over the pilot bushing in drum. Install the (8) capscrews (item # 34) and torque the capscrews to 103 ft lb (139 Nm) to securely seat the clutch to the drum Rotate the drum to align the clutch slots with the shaft keyways. Lightly grease (4) dowel pins and (8) balls. Use molybdenum disulfide or graphite bearing grease. Insert the (4) dowel pins (item #55) and (8) balls (item #24). In the engaged position the balls are nearly flush with the clutch. Lightly grease the internal and external groove and bore in locking ring (item # 9) and clutch (item #8). Slide locking ring onto the clutch. When fully engaged, the locking ring touches the clutch flange and there is.71 to.73 inches between the locking ring and the end of the clutch.

14 (18) 11 Place (4) springs (item # 63) over (4) roll pins on retainer plate (item #59). Install spacer (item #21) and retainer plate and secure to clutch using (4) capscrews (item # 30). Tighten capscrews to 9.7 ft lb (13 Nm) each. Firmly seat the retainer ring (item # 61) into drum shaft groove. Set the shifter assembly so that the screw heads engage the external groove in the locking ring. Push the clutch housing (item #15) onto the drum shaft and latch the shifter assembly in the engaged IN position. Insert the (2) capscrews (item #32) (19) Attach mounting angles (item # 4) to winch assembly. Use capscrews (item #35) and lockwashers (item #44) to secure. Tighten capscrews to 173 ft lb (235 Nm). Insert plug (item #54) into hole in bottom of gear housing. Remove plugs (items #52 & #49) from top of gear housing. Pour 3 pints of E.P. 140 oil into hole and replace plugs. Check the action of the clutch by shifting and freespooling the winch drum several times (20) The shift linkage on top of the clutch housing is adjusted at the factory to provide reliable shifting of the Dow-lok clutch. When reassembling, it may be necessary to re-adjust it as follows: Attach the bracket (item #26) to the clutch housing with the capscrews (item #31). Attach the shifter lever assembly to the yoke using the clevis pin and cotter pin (items #45 & #46). With the clutch in the engaged IN position, the notch in the shifter shaft should be latched onto the bracket with a minimum of shaft end play so that the clutch is securely latched IN. If adjustment is needed, loosen the large jam nut and screw the shaft into or out of the clevis as needed. Securely tighten the jam nut

15 12 H 700 Less Brake With Counterbalance Valve Dimensional 13

16 H 700 Less Brake With Counterbalance Valve Parts Drawing

17 H 700 Less Brake With Counterbalance Valve Parts List ITEM # Qty PART NUMBER DESCRIPTION ITEM # Qty PART NUMBER DESCRIPTION SHIFTER ASSEMBLY CAPSCREW-5/8-11UNC X 3.50 LG HX HD GR8 Z/P MOTOR COUPLING ASSEMBLY CAPSCREW 3/8-16NC X 1 LG SOC. HD ADAPTER CAPSCREW-3/8-16 X.75 LG SOC HD MOUNTING ANGLE CAPSCREW 3/8-16NC X 1-1/2 LG SOC HD LOC-WEL BUSHING CAPSCREW 3/8-16NC X 2-1/2 LG SOC HD CABLE ANCHOR CAPSCREW 1/2-13NC X 1-3/4 LG SOC HD CAP-BEARING CAPSCREW #10-24 X 1/2 LG CLUTCH NUT # LOCKING RING NUT 3/8-16NC GEAR HOUSING COVER LOCKWASHER-5/8 MED SECT Z/P SHOE-DRAG BRAKE COTTER PIN DRUM CLEVIS PIN WORM GEAR GASKET-BEARING CAP GEAR HOUSING GASKET-GEAR HSG COVER CLUTCH HOUSING FITTING-RELIEF1/8-27NPTF, 15 PSI MAX KEY LUBE FITTING KEY MOTOR-HYD (11.9) CU IN 2000 SERIES DRUM SHAFT QUAD RING SHIFTER SHAFT REDUCER BUSHING ADAPTER PLATE PIPE PLUG SPACER ROLL PIN WORM DOWEL PIN YOKE ROLL PIN BALL-POPPET 3/8 DIA ROLL PIN BEARING RETAINER PLATE SHIFTER BRACKET SEAL BUSHING RETAINER RING BUSHING SPRING SHIFTER COVER SPRING CAPSCREW-1/4-20NC X.75 LG HX HD GR5 Z/P SPRING CLUTCH CAPSCREW 5/16-18NC X 3/4 LG, HXHD COUNTERBALANCE VALVE CAPSCREW-3/8-16 X 1.0 LG HX HD GR5, Z/P THRUST WASHER CAPSCREW 3/8-16NC X 1 LG HXHD GR5 NYLOK PATCH SPACER-BRAKE DISC CAPSCREW 1/2-20NF X 1 LG, HXHD, GR5 15

18 NOTES 16

19 NOTES 17

20 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 Tulsa, Oklahoma Telephone: (918) FAX: (918) OM A