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Ramsey Winch 400, Operating, Service And Maintenance Manual, Page: 3 / 30

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3

TABLE OF CONTENTS

INTRODUCTION

…………………………………………………….

1

WARRANTY INFORMATION

…………………………………………………….

1

SPECIFICATION

…………………………………………………….

1

TECHNIQUES OF OPERATION

…………………………………………………….

2

SAFEGUARDS:  WARNING

…………………………………………………….

2

WINCH MAINTENANCE

…………………………………………………….

3

WINCH MOUNTING

…………………………………………………….

4

CABLE INSTALLATION

…………………………………………………….

4

ADJUSTING THE OIL COOLED SAFETY BRAKE

…………………………………………………….

4

SERVICING OF THE OIL COOLED SAFETY BRAKE

…………………………………………………….

5

RE-ASSEMBLING AND CHECKING THE BRAKE

…………………………………………………….

6

TEST FOR PROPER BRAKE ASSEMBLY

…………………………………………………….

6

INSTRUCTIONS FOR CHECKING ASSEMBLY

…………………………………………………….

7

ARRANGEMENT AND SETTING OF WORM BRAKE

HYDRAULIC SYSTEMS/PERFORMANCE CHARTS

…………………………………………………….

8

TYPICAL LAYOUT/HYD. SYSTEM DIAGRAM

…………………………………………………….

9

TROUBLE SHOOTING TIPS

…………………………………………………….

9

INSTRU CTIONS FOR OVERHAUL OF

RAMSEY MODEL 400/H-400 SERIES LEVER STYLE WINCHES

DISASSEMBLY

…………………………………………………….

10-13

RE-ASSEMBLY

…………………………………………………….

13-15

DIMENSIONAL DRAWING

…………………………………………………….

16-18

PARTS LIST AND PARTS DRAWING

…………………………………………………….

19-25

LIMITED WARRANTY

…………………………………………………….

26

Summary of Contents for 400

Page 1: ...WINCHES INCLUDES 400 Y 400 H 400 HY 400 AND MODELS EQUIPPED WITH OPTIONAL ADJUSTABLE AUTOMATIC OIL COOLED SAFETY BRAKE G 400 GY 400 HG 400 HGY 400 CAUTI0N READ AND UNDERSTAND THIS MANUAL BEFORE INSTAL...

Page 2: ......

Page 3: ...TY BRAKE 5 RE ASSEMBLING AND CHECKING THE BRAKE 6 TEST FOR PROPER BRAKE ASSEMBLY 6 INSTRUCTIONS FOR CHECKING ASSEMBLY 7 ARRANGEMENT AND SETTING OF WORMBRAKE HYDRAULIC SYSTEMS PERFORMANCE CHARTS 8 TYPI...

Page 4: ...ope ratings INTRODUCTION Rated Line Pull 1st layer lbs 10 000 Kgs 4 530 Shipping Weight 400 Y 400 125 lbs 57 Kgs G 400 GY 400 135 lbs 61 Kgs H 400 HY 400 150 lbs 68 Kgs HG 400 HGY 400 160 lbs 73 Kgs 2...

Page 5: ...d is off the cable Grasp the clutch handle and move it toward the cable drum to the OUT position The cable may now be pulled from the cable drum by hand 2 TO ENGAGE CLUTCH move the clutch handle away...

Page 6: ...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 4 Check the wi...

Page 7: ...all the cable onto the cable drum taking care to form neatly wrapped layers ADJUSTING THE OIL COOLED WORM BRAKE The oil cooled fully adjustable automatic safety brake operates in the worm housing lubr...

Page 8: ...5 Remove the retainer plate composition brake disc cam plate and balls Note slots balls are in 6 Inspect parts as follows a Composition brake discs are 1 4 thick when new Replace if thinner than 3 16...

Page 9: ...ce with the mounting screws Install drain plug and add 1 3 4 pint all purpose E P 140 oil 10 Turn winch in the hoisting direction at least one turn of the input shaft 11 Turn the adjusting screw in un...

Page 10: ...1 3 The side of the winch that the input shaft is on The INPUT SHAFT IS NORMALLY TOWARD THE CAB Whether the winch has the gear box on the right or on the left side of the winch does not affect the bra...

Page 11: ...P M vs gallons per minute G P M and 2 Line pull lbs first layer vs working pressure P S I STATIC solid line refers tq hoisting a suspended load from rest DYNAMIC dotted line refers to maintaining the...

Page 12: ...ace gasket LOAD DRIFTS DOWN 1 Safety brake has become worn 1 Replace brake disc See Pages Diagram 1 2 Safety brake out of adjustment 2 Turn adjus ng bolt clockwis l 4 turn or un l load does not dri WI...

Page 13: ...n 3 Remove key item 18 from worm shaft Remove bearing cap item 5 and gasket item 43 by un screwing six capscrews item 33 Remove seal item 51 from bearing cap and press new seal into place Drag brake d...

Page 14: ...unscrewing six capscrews item 33 Remove worm item 26 and bearings item 30 from gear housing Use a soft hammer to gently tap input end of worm and drive worm and bearing from gear housing Once worm ha...

Page 15: ...cessary by pressing old bushing from gear housing Press new bushing into place and insert new quad ring into groove inside of bushing 9 Check drum bushings items 3 56 for signs of wear Replace if nece...

Page 16: ...0 onto worm item 26 NOTE Be sure that thick shoulder of bear ings outer race side with manufacturer s name and part number is out away from worm threads Press bearing and worm into gear housing Slip g...

Page 17: ...item 54 and thrust bearing item 25 over end of worm item 21 and into housing Attach adapter item 1 with gasket item 41 to housing us ing six item 32 capscrews Tighten cap screws to 12 ft lbs 16 Nm eac...

Page 18: ...ent If only the clutch is replaced the new detents are to be drilled on the side of the shaft oppo site the old detents Apply grease to bushing in clutch housing assembly item 14 Set clutch housing on...

Page 19: ...HES MM c INCHES MM D INCHES MM E INCHES MM F INCHES MM 400 8 44 214 4 11 63 295 4 3 63 92 2 8 75 222 3 7 87 199 9 15 75 400 1 Y 400 7 00 177 8 8 75 222 3 4 00 101 6 7 32 185 9 9 31 236 5 12 88 327 2 M...

Page 20: ...CHES MM c INCHES MM D INCHES MM E INCHES MM F INCHES MM 400 8 44 214 4 11 63 295 4 3 63 92 2 8 75 222 3 7 87 199 9 15 75 400 1 Y 400 7 00 177 8 8 75 222 3 4 00 101 6 7 32 185 9 9 31 236 5 12 88 327 2...

Page 21: ...21 MODEL H 400 SHORT COUPLING DIMENSIONAL DRAWING...

Page 22: ...22 56 3 MODEL 400 EXPLODED VIEW...

Page 23: ...X 1 2 12 1 334009 GEARY LH 40 1 416112 SET SCREW 5 16 18NC X 3 4 13 1 334016 GEAR RH 41 12 418163 LOCKWASHER 5 16 14 1 338009 HOUSING CLUTCH 42 8 418198 LOCKWASHER 7 16 15 1 338010 HOUSING GEAR 43 8 4...

Page 24: ...24 58 5 MODEL H 400 EXPLODED VIEW...

Page 25: ...1 332138 DRUM 400 41 1 416112 SET SCREW 5 16 18NC X 3 4 13 1 334016 GEAR RH 42 6 418163 LOCKWASHER 5 16 14 1 338009 HOUSING CLUTCH 43 8 418198 LOCKWASHER 7 16 15 1 338010 HOUSING GEAR 44 2 442182 GASK...

Page 26: ...26 57 3 MODEL H 400 SHORT COUPLING EXPLODED VIEW...

Page 27: ...2 12 1 338269 HOUSING GEAR 41 2 442182 GASKET 13 1 342024 KEY SQ END 42 1 442183 GASKET 14 NO LONGER USED 43 3 456006 FITTING LUBE 15 2 342120 KEY RD END 44 1 456008 FITTING RELIEF 16 2 450017 KEY BA...

Page 28: ...68080 WORM RH 110 2 400007 BALL 111 4 414111 CAPSCREW 5 16 18 NC X 1 112 2 414398 CAPSCREW 3 8 24NF X 1 3 4 113 1 414603 CAPSCREW 1 2 20UNF X 1 3 4 114 6 414865 CAPSCREW 5 16 18 NC X 1 115 1 418067 NU...

Page 29: ......

Page 30: ...for special or consequential damages RAMSEY WINCH makes no war ranty in respect to accessories such as being subject to the warranties of their respective manufacturers RAMSEY WINCH whose policy is on...

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