Ramsey Winch CABLE TENSIONER 800/H-800 256107 - Manual

INSTALLATION INSTRUCTIONS FOR KIT #256107
CABLE TENSIONERS FOR 800/H-800 SERIES WINCHES
This tensioner kit is designed specifically for Ramsey Winch Model 800/H-800 series winches. Kit #256107
is for both underwound and overwound winches.
INSTALLATION PROCEDURE
Disengage the winch clutch and freespool all the cable except for the last wrap off the winch. Lay cable out
in a straight line behind the truck to prevent kinking. Mark mounting hole centers as shown on the following
page. Place cable tensioner assembly over marked hole positions, orienting it correctly for either an
overwound or underwound winch (see following page). Observe location of tensioner plate and center it
between the drum flanges. Adjust hole locations as necessary to maintain centered position. Drill two .562
diameter holes through the rear angle as shown on the following page.
Place the supplied mounting bolts through the mounting holes of the tensioner bracket. Position the bracket
over the previously drilled holes in the rear angle, allowing the bolts to fall through the holes. Loosely attach
the washers and nuts.
Center the tensioner plate between the drum flanges with a scale or tape measure and tighten the bolts
securely (87 ft-lbs. of torque).
If you removed the cable entirely, or this is a new installation, the cable tensioner is not intended to be
energized on a bare drum. Before increasing the tension on the cable tensioner, engage the clutch and run
the winch in the reel in direction winding one full wrap of cable on the drum. This prevents damage to the
cable tensioner.
Engage the clutch and run the winch in the reel in direction, winding about five wraps of cable onto the
drum and stop. Using a hammer, tap these five wraps tightly against the side of the flange closest to the
cable anchor on the cable drum. Finish winding all the cable onto the cable drum. As cable winds onto the
drum, watch the tensioner. Tensioner must be free to move without obstruction to function properly. If
tensioner touches any surrounding structure, correct the problem.
To adjust the freespool effort of the tensioner, turn the adjustment nut at the top or bottom of the tensioner
assembly (see drawing on following page). This will adjust the spring height. Start adjusting the tensioner
with the spring height at 5.50”. Disengage the winch clutch and freespool some cable off the drum. Adjust
the spring tension to achieve the desired freespool effort that also prevents “bird nesting” of the cable.
OPERATION
Once you have adjusted the spring tension to the desired level, only minor adjustments may be required if
the setting drifts.
KI-912592-1205-D
RAMSEY WINCH COMPANY
P.O. BOX 581510
TULSA OK 74158-1510
www.ramsey.com