Ramsey DC-200 User Manual

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Page 1

OPERATING, SERVICE AND MAINTENANCE MANUAL

MODEL DC-200 SERIES

RAM-LOK®EQUIPPED

INDUSTRIAL LOW-MOUNT WINCHES

INCLUDES: DC-200/DC-246, DC-24-200/DC-24-246.

DCY-200/DCY-246, DCY-24-200/DCY-24-246 AND MODELS EQUIPPED WITH OPTIONAL ADJUSTABLE, AUTOMATIC OIL COOLED SAFETY BRAKE: DCG-200, DCYG-200 SE-

RIES WINCHES

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE SAFEGUARDS AND WARNINGS!

Page 2

TABLE OF CONTENTS

INTRODUCTIO

N................................................................................................1

WARRANTY INFOR MATION............................................................................

SPECIFICATION............................................................................................... 1

TECHNIQUES OF OPERATION....................................................................... 2

WARNINGS....................................................................................................... 2

WINCH MAINTENANCE................................................................................... 3

WINCH MOUNTING.......................................................................................... 4

ELECTRICAL CONNECTIONS......................................................................... 4

CABLE INSTALLATION.................................................................................... 4

ADJUSTING THE OIL COOLED SAFETY BRAKE........................................... 4

SERVICING OF THE OIL COOLED SAFETY

RE-ASSEMBLING

AND CHECKING THE

BRAKE......................................5

BRAKE........................................... 6

TEST FOR PROPER BRAKE ASSEMBLY....................................................... 6

INSTRUCTIONS FOR CHECKING ASSEMBLY

ARRANGEME N T AND SETTING OF WORM BRAKE................. .....................

TROUBLE SHOOTING GUIDE..................................................................... 8-9

INSTRUCTIONS FOR OVERHAUL OF

RAMSEY MODEL DC-200 SERIES RAM-LOK®

WINCHES

DISASSEMBL Y REASSEMBL Y

............................................................................10-13

.............................................................................13-16

DIMENS IONA L DR AW ING............................................................................. 17

PARTS LIST AND PARTS DRAW ING SOLENOID AND SWITCH ASSEMBLY PARTS TEST PROCEDURE FOR TEST PROCEDURE FOR

MOTOR ASSEMBLY PARTS

SOLENOID.......................................................... 22

MOTOR............................................................... 23

LIST................................................................ 24

........................................................18-20

LIST.................................... 21

LIMITED WARRANTY.................................................................................... 25

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(

RAMSEY ELECTRICAL WINCH MODEL DC-200 SERIES

PLEASE READ THIS MANUAL CAREFULLY.

This manual contains useful ideas in obtaining the most efﬁ cient 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 speciﬁ cations. 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 ﬁ ll 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

Rated Line Pull 1st Layer (l bs.)................................................................................................ 8,000

(kgs.)................................................................................................ 3,630

Total Gear Reduction: D C -200..............................................................................

DC-246.................................................................................................... 360

Weight: DC-200/DC-246 (long drum) ..................................................................

DCY-200/DCY-246 (short drum)..............................................................

MAXIMUM GEAR BOX OIL TEMPERATURE SHOULD NOT EXCEED................................................ 2500F

Layer of Cable 1 2 3 4 Rated Line Pull Lbs. 8,000 6,700 5,700 5,000

per layer

Long Drum Cable

capacity per layer

"Y"

Short

Drum

cable c apaci ty per layer

Kgs. 3,620 3,030 2,580 2,260

Ft. 25 60 95 140 M. 7 18 28 42

Ft.

15 30 55

NO LOAD 2000#LOAD 4000# LOAD 8000# LOAD

Line Speed

VOLTS (MPM)

FPM FPM FPM FPM

AMPS

(MPM)

AMPS

(MPM) DC-200/DCY-200 12 14 65 7 110 5 180 3.5 DC-24-200/DCY-24-200

(4.3). 30 (2.1). 50

DC-246/DCY-246 12 16.5 70 8.5 140 5.5 DC-24-246/DCY-24/246

(5)· 35 (2.5). 70

*These speciﬁ cations are based on recommended 3/8 inch dia. extra improved plow steel wire rope or equivalent.

Winch only conforms to SAE J706. For SAE qualiﬁ cation of mounting angles, if applicable, consult Ramsey Engineering.

....................... 470

(MPM)

AMPS

1.5). 90

1.7).

(1.1).

200

100

116 lb. ( 52. 6 105 lb. ( 47. 6

AMPS

280 140

3.5 330

1.1). 160

Kgs.) Kgs.)

NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.

Winch duty cycles are shown below:

MINUTES

180

270 360

AMPS

MINUTES

90 120 160 190

AMPS

12V 24 V

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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 conﬁ dence 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 blanket, jacket or tarpaulin over the cable about six feet behind the hook. This will slow the snap back of a broken cable and could prevent serious injury.

Check oil level of winch every six months. Replace oil annually or more often if winch is used frequently. Use 3/4 pint of all purpose E. P. 140 oil in the worm gear housing and 1/2 pint SAE 20 for spur gear box. If the oil is contaminated with metallic particles, inspect winch for cause of abnormal wear. Periodically check all electrical connections and mounting bolts. Tighten hardware if necessary.

The minimum ampere-hour rating of vehicle battery should be 70, and used with at least a 40 amp alternator. An Auxiliary battery is recommended to supply additional battery power. Inspect the cable frequently. If the cable becomes frayed with broken strands, replace immediately. Cable and hook assembly may be purchased from a Ramsey distributor. The RAM-LOK® semi-automatic clutch allows rapid unspooling of the cable, from cable drum, for hooking onto a load. The clutch is operated by the “T-handle”, located on the end of the winch, 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 clutch handle, rotate it counter-clockwise 90 now locked out and the cable may be pulled off by hand.

2. TO ENGAGE CLUTCH, pull outward on the handle, rotate it clockwise 900 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. 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.

WARNINGS

and release. The clutch is

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 IN USE. 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 PERSONNEL. A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD

THE LOAD. CABLE CLAMP IS NOT DESIGNED TO HOLD LOAD. DISCONNECT THE REMOTE CONTROL SWITCH FROM WINCH WHEN NOT IN USE. A RAMSEY

PART NO. 282053 SAFETY ON-OFF SWITCH IN YOUR VEHICLE IS RECOMMENDED.

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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.

A. WEEKLY

1. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine loca tion and repair.

2. Check the pressure relief plug in top of the gear housing. Be sure that it is in good operat ing condition so that hot oil gasses may escape.

3. Lubricate cable with light oil.

B. MONTHLY

1. Lubricate the various grease ﬁ ttings located in the cable drum, end bearing, clutch hous- ing or clutch operating linkage. Any good grade of moly-disulﬁ de containing grease is acceptable.

2. Check the action of the sliding clutch, making sure it is fully engaging and disengaging with the cable drum. Remove the plastic plug in top of the housing and observe if the clutch is fully engaging. If clutch is not fully engaging, inspect clutch shifter assembly parts, check for damage or excessive wear and replace as necessary. 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.

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 the torque setting of the oil cooled worm brake. Make any adjustments re quired, following the procedure described in ADJUSTING THE OIL COOLED WORM BRAKE in the Owner’s Manual.

5. Check alignment of chain and sprockets and adjust as required to minimize wear.

6. 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 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.

3. Reﬁ ll the winch to the oil level plug with all purpose EP 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.

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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 DC-200 Series winches are furnished with recommended mounting angles. Angle size is 1/4 x 2-1/2 x 2-1/2 x 36” Lg. high strength (50,000 PSI yield) steel angle.

ELECTRICAL CONNECTIONS

See dimensional drawing on page 17. Using a power cable with appropriate end terminals, connect the positive (+) battery terminal to the 5/16” dia. stud on the plastic solenoid cover on the winch. IMPORTANT: hold inner nut on stud with a wrench while tightening outer nut. Using a ground cable with appropriate end terminals, connect the negative(-) battery terminal to the motor isolated ground terminal. In applications where the chassis is non-grounded, a jumper wire (#440315) will be required between the winch and the motor isolated ground terminal. This ground is required to insure a sufﬁ - cient ground to operate the solenoid assembly (see diagram below). For distances up to 15 feet from battery to winch, use #2 Ga. wire for the above connections. For distances greater than 15 feet, use wire larger than #2 Ga.

WINCH WILL NOT OPERATE UNLESS GROUND CABLE IS INSTALLED FROM THE ISOLATED GROUND TERMINAL TO THE NEGATIVE BATTERY POST.

(SEE DIAGRAM BELOW)

NEGATIVE BATTERY POST

Isolated Motor Ground

CABLE INSTALLATION

ISOLATED GROUND TERMINAL

GROUND CABLE

SEE ILLUSTRATION

BELOW

JUMPER CABLE (#440315) MUST BE INSTALLED ON WINCH FROM MOTOR ISOLATED GROUND STUD TO GEAR HOUSING COVER BOLT AS SHOWN FOR NON GROUNDED CHASSIS APPLICATIONS.

For non-grounded chassis applications a jumper wire (#440315) is required to ground the solenoid assembly.

1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of cable, oppo site 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 neatly wrapped layers.

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WORM BRAKE ADJUSTMENT

ADJUSTING THE OIL COOLED WORM BRAKE

The oil-cooled, fully adjustable, automatic safety brake operates in the worm housing lubricant, all parts being submerged in oil. When the brake wears to the point that the load begins to drift, the brake can be adjusted as follows:

1. Loosen the lock nut on the adjusting screw.

2. Tighten the brake by turning the adjusting screw clockwise. CAUTION: Only 1/4 turn is usually required to adjust the brake. Over-tightening can cause over

heating, and damage to the brake parts. Tighten the lock nut after adjustment is completed. If the brake does not respond to adjustment then a new leaf spring and brake disc is needed. A torque wrench can be equipped with a special adapter to ﬁ t the input shaft (worm) of the winch. The adapter can be made by welding a nut to the end of a piece of tubing as shown in the following ﬁ gure.

After welding the cap and nut to the tubing, slot the tubing as shown. This will allow the special adapter to slide over the keyway and will then act as a large socket. A torque wrench can then be used to apply the proper torque. Turn the torque wrench so that the drum turns in the spool out direction or lowering direction. The torque rating for the Model 200/246 should be 8 to 13ft. lbs. (D-200, 13 to 18ft. lbs.).

If the torque wrench does not show the proper value as it turns the worm brake adjusting bolt should be turned clockwise 1/4 turn. Each time the adjusting bolt is turned, check the torque reading. Continue this procedure until the proper torque reading is achieved. Then tighten the lock nut.

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SERVICING OF THE OIL COOLED SAFETY BRAKE

1. Remove the drain plug and drain the worm gear oil from the worm housing.

2. Back off the lock nut, then the adjusting screw, both two turns or more by turning them counter-clockwise.

3. Remove the cover mounting screws.

4. Remove the cover along with coil spring and leaf spring.

5. Remove the retainer plate, composition brake disc, cam plate and balls. Note, the slots the balls are in.

6. Inspect parts as follows: a). Composition brake discs are 1/8” thick when new. Replace if thinner than 0.080” or if

surfaces are glazed or burnt. b). Inspect the ﬂ at, ground surface of the cam plate and retainer plate for glazing, warpage,

or other damage. Glazing can be removed by scraping carefully. c). Inspect the leaf spring. It should be bowed 1/8”.

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BRAKE - CHECKING / RE-ASSEMBLY AND TESTING

BRAKE RE-ASSEMBLY

1. Press brake hub into place over worm shaft and key.

2. Assemble ball into appropriate slots of cam. (Refer to diagram 1, page 5). Use stiff grease to hold balls into place and slide cam over end of worm. Be sure that balls are secure, between cam slots and hub slots. Refer to Page 7 to determine proper ball slot setting.

3. Install brake disc.

4. Install retainer plate, smooth side toward brake disc.

5. Install the gasket on the cover with a small amount of grease or sealer.

6. The coil spring goes over the adjusting screw on the inside of the cover.

7. Install the notches of the leaf spring on the pins protruding through the cover. The hollow side of the leaf spring goes toward the brake.

8. Install brake housing cover, making sure the protruding pins go through the leaf spring and into the holes in the retainer plate.

9. Bolt cover into place with the mounting screws. Install drain plug and add 1 pint all purpose EP 140 oil.

10. Turn winch in the hoisting direction at least one turn of the input shaft.

11. Turn the adjusting screw in until it is ﬁ nger tight.

TEST FOR PROPER BRAKE ASSEMBLY

After the brake has been adjusted to the proper torque setting disengage clutch. Start vehicle engine and run winch in the reel in (hoisting direction). Allow winch to run in this direction for one minute.

Place your hand on the safety brake housing. If housing is not hot to the touch then run winch in the reverse direction (cable out) for one minute. Brake housing should begin to heat.

When these conditions exist, proper installation has been made. If heating becomes noticeable when running the winch in forward rotation (hoisting direction), the brake should be again disassembled. When disassembled, place the brake balls in the alternate set of slots in the cam plate, then carefully follow the instructions for re-assembling and checking the brake.

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INSTRUCTIONS FOR CHECKING ASSEMBLY ARRANGEMENT

AND

SETTING OF WORM BRAKE

When the worm brake is assembled the brake must be set with the balls in the #1 or the #2 set of cam slots. (View A-A, page 5). It is indicated on the name plate whether the balls were installed in the #1 or the #2 slots at the factory.

Three factors determine which slots the balls should be in:

1. Direction cable winds on the drum. It normally WINDS OVER THE TOP of the drum barrel.

2. 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 brake setting.

EXAMPLE: When cable winds over the top of the drum, winch has a right cut gear and input shaft is toward the cab (diagram 2) , then the balls need to be in the #2 cam slots.

If any one of these three factors differ from those stated above, the balls need to be in the #1 slots in the cam. A second change in these factors requires the original arrangement,and if all three factors are different, the balls need to be in the #1 slots. (See page 5 and 6 for disassembly and assembly instructions).

DIAGRAM 2

Input side of winch toward cab

Cable winds over top

Page 11

TROUBLE SHOOTING GUIDE

CONDITION

CLUTCH INOPERATIVE OR BINDS UP.

OIL LEAKS FROM HOUSING.

LOAD DRIFTS DOWN.

CABLE DRUM WILL NOT FREE SPOOL.

CABLE BIRDNESTS WHEN CLUTCH

IS MOTOR RUNS IN ONE DIRECTION

ONLY.

MOTOR RUNS, BUT DRUM DOES NOT TURN.

DISENr,Ar,F:rr

POSSIBLE CAUSE

1. Dry or rusted shaft.

2. Bent yoke or linkage.

3. Clutch j aws are contact.

1. Seal damaged or worn.

2. Too much oil.

3. Damaged gas ket.

1. Safety brake has becomewom.

2. Safety brake out of adjustment.

1. Winc h no t m o u nt e d squarely, causing bearings to bind drum .

1. Drag brake disc worn.

1. Inoperative solenoid or stuck soleno id.

2. Inoperative switch.

3. Broken wire or connection.

1. Clutch not engaged.

2. Sheared drum shaft key.

3. Stripped bronze gear.

4. Parted shaf t .

end

CORRECTION

1. Clean and lubricate.

2. Replace yoke or shaf t assembly.

3. See TECHNIQUES OF OPERATION.

1. Replace seal.

2. Drain excess oil. Refer to TECHNIQUES OF OPERATION.

3. Replace gasket.

1. Replace brake disc. (S ee Page 5, Diagram

2. Tum adj usting bolt wise 1/4 tum or until

load does not drift.

1. Check m ounting. Ref er to WINCH MOUNTING Page 4.

)

clock-

bad

1. Replace discs.

1. Jar so leno id t o free

contacts. Check by applying

12 volts to coil terminal should make an audible click when energized).

2. D ise ng ag e w inc h c l utc h remove armature lead. Remove switch plug from hood. Raise connector cover on hood and with a screw driver, short the bottom

two pins. Solenoid should

click. S hort the two left hand p ins. The ot her solenoid should operate.

If bo th sole no ids check for a broken wire in switc h cabl e.

3. Check for loose connection on switc h a nd swi tc h connector.

1-4. If clutch engaged b ut

symptom still exists, it will be necessary to assemble winch to determine cause and repair.

operate

dis-

(

Page 12

CONDITION

POSSIBLE CAUSE

CORRECTION

MOTOR RUNS EX TREMELY HOT.

MOTOR RUNS, BU T WITH

INSUFFICIENT POWER, OR WITH LOW LINE SPEED.

MOTOR WILL NOT OPERATE.

1. Long period of operation.

2. Insufficient b att er y.

3. Electrical cables from battery to winch too sma ll

4. Bad electr ica l connections.

5. Insufficient charging system.

1. Inoperative solenoid or stuck solenoid.

2. Inoperative sw itc h.

3. Inoperative motor.

4. Loose co nnec t ions.

1. Cooling-off penods are esse ntia l to pre vent ov erheating.

2. Check battery terminal voltage under load. If 10

s or les s, rep lace

volt parallel another battery to it at motor terminal.

3. Must be #2 Ga. wire for

distances up to 15 feet from battery to winch. Use larger than #2 Ga. for distances greater than 15 f eet.

4. Check all connections for looseness or corrosion; Tighten, clean and grease.

5. Replace with

capacity charging syst em.

1. Ja r so lenoid to fre e contacts. Check by applying

12 volts to coil terminal

(it should make an audible

click when energized).

2. Disengage winch clutch or remove armature lead. Remove switch plug from hood. Raise connector cover on hood a driver, short the bottom two pins. Solenoid s hould click. S hort t he two left pins. The other sole noid should operate. If both

solenoids operate, check for a broken wire in

switch cable.

3. If solenoids operate, check for voltage at armature post; replace motor.

4. Tighten connections on bottom side of hood and on motor.

larger

nd w it h a sc re w

Page 13

NOTES

Page 14

INSTRUCTIONS FOR OVERHAUL OF RAMSEY

MODEL DC-200 SERIES RAM-LOK

DIS-ASSEMBLY

1. Drain oil from gear housing by remov ing (item #54) plug from bottom of gear housing. Remove relief ﬁ ttings and re- ducer (items #50 & #53) from top of gear housing. Remove mounting angles (items #4 & #5) from winch by removing hardware shown.

2. Drain oil from spur gear box by removing (item #54) plug. Remove cover and gasket (items #9 & #44) from spur gear housing by unscrewing twelve capscrews (item #28). Slide gear (item #12) from end of worm shaft (item #23). Remove spur gear shaft (item #21), with gears attached. Check bearings (item #24) and thrust washers (item #68) for signs of wear, replace if necessary. Remove old bearings and press new bearings into place. Remove solenoid assembly (item # 2) by unscrewing capscrews (items #30 & #34). Disconnect solenoid cables from motor (item #51). Make note of which terminals cable are attached to.

3. Remove key (item #19) and snap ring (item #65) from worm shaft. Remove motor (item #51) from spur gear housing (item #16) by removing (3) nuts and lockwashers (items #39 & #41). Unscrew (4) capscrews (item #33) to remove spur gear box (item#16) and gasket (item #43) from gear housing. Replace lip seals (items #62 & #64) by pressing old seals from spur gear housing and pressing new seals into place.

Page 15

4. Slide clutch housing (item #17) from end of drum shaft. Slide jaw clutch (item #7) from end of drum shaft.

Remove (2) keys (item # 47) from keyways . A screw driver can be used, at notch, to aid in remov al of keys. Once keys have been removed, drum (item#10) and thrust washer (item #70) can be removed from drum shaft. Parts under drum, thrust washer (item #69), spring and disc (items #66 & #42) should also be removed.

5. Remove bearing cap (item #6) from gear housing by unscrewing four capscrews (item # 29 ). Remove worm (item #23 ) and bearing (item #25) from gear housing. Use a soft ham mer to gently tap input end of worm and drive worm and bearing from gear housing. Once worm has been removed from housing, bear ing can be pressed from end of worm.

6. Remove gear housing cover (item #8) from gear housing (item #18) by unscrewing ﬁ ve remaining capscrews (items #29). Place capscrew into two tapped holes of cover and tighten. This will pull the cover loose from gear housing.

Remove cover gasket (item #45) and pull shaft (item #22), with gear attached, and spacer (item #70) from gear housing.

Check for signs of wear to worm (item #23) and bearings (item #25). Replace if neces sary.

For models with optional worm brake refer to page 5, SERVICING OF THE OIL COOLED SAFETY BRAKE, for disassembly and page 6, for re-assembly instructions.

Page 16

7. Check for signs of wear on gear teeth. If replacement of gear is necessary, replace as follows: a) Press gear (item #14) from shaft (item #22). 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 #48) into keyways. Press gear (item #14) over shaft and keys. Gear must be centered over keys.

8. Remove seal (item #63) from back of gear housing (item #18). Check bushing (item #27) for signs of wear. Press bushing (item #27) from gear housing and replace if necessary. Press new bushing and seal back into place.

9. Check drum bushings (item #26) for signs of wear. Replace if necessary by pressing old bushings from drum (item#10) and pressing new ones into place.

10. Examine shifter assembly (item #1) for damage to yoke. Yoke should be ﬁ rmly attached to shaft, yet, able to swivel freely around shaft. Replace if necessary by removing pin (item #58) from handle (item #15). Remove rubber plug (item #59) from housing. Unscrew set screw enough to allow shifter assembly to be removed from housing.

Check clutch housing bushing (item #26) for signs of wear. Remove if necessary by press ing old bushing from housing (item #17) and pressing new one into place.

Install new shifter assembly (item #1) by plac ing end of shaft, opposite yoke, through spring (item #67) and into housing item(#17). Attach (item #15) handle to shaft using roll pin (item #58). Tighten setscrew, in housing, enough to allow shifter assembly to operate properly. Replace rubber plug.

Page 17

11. Check cover bushing (item #8) for signs of wear. Re place if necessary by removing old bushing and press ing new bushing into place.

12. Check pinion gear on motor for signs of wear. If necessary replace motor (item # 51).

13. Check gears of spur gear shaft assembly for signs of wear, replace if necessary. Press old gears from shaft (item #21). Tap key (item #20) into keyway of shaft (item #21). Press shaft through gears so that gears are centered on shaft and key.

RE-ASSEMBLY

14. Apply grease to end of shaft, opposite gear. Apply grease to bushing in gear housing (Item#18). Place greased end of shaft through spacer (item #71) and bushing in gear housing (item #18). Place gasket (item #51) onto gear housing cover (item #8). Apply grease to gear end of shaft and bushing in cover.

Place cover onto shaft and secure to housing with ﬁ ve (item #29) capscrews at ﬁ ve lower holes.

Page 18

15. Place winch, with gear housing cover down, on work bench. Drum shaft should be in vertical position. Slide thrust washer (item #69) over drum shaft and slide downwards until washer rests on gear housing. Set springs (item #66) and drag brake disc (item #42) into pockets of gear housing. Grease bushings in drum (item #10). Slide drum assembly onto drum shaft with drum jaws upward.

16. Slide thrust washer (item #70) over end of drum shaft. Press drum (item #10) downward to compress drag brake springs in gear housing.

Insert keys (item #47) into keyways with sharp edge of keys pointing outward and notched end of keys up ward. A rubber or brass mallet will be needed to gently tap keys into position.

Apply grease to keys and end of shaft. Place jaw clutch (item #7) over end of shaft and slide jaw clutch over keys. Set clutch housing (item #17) over end of drum shaft. Pull jaw clutch (item#7) upward, toward clutch housing, enough to allow yoke, in clutch hous ing, to ﬁ t properly in groove around jaw clutch.

Page 19

17. Press bearing (item #25) onto worm (item #23) NOTE: Be sure thick shoulder of bearings outer race (side with manufacturer's name and number ) is out, away from worm threads. Press bearing and worm into gear housing. Slip gasket (item #43) onto bearing cap (item #6). Use four capscrews (item #26) to secure cap to gear hous ing. Torque capscrews to 7 ft-lbs. (9.4 Nm) each.

Attach solenoid assembly (item #2) to gear hous ing. Use two (item #34) capscrews and three (item #30) capscrews with three ﬂ atwashers (item #40). Tighten capscrews to 7 ft-lbs. (9.4 Nm) each. Insert plug (item #56) into tapped hole of cover. Permatex may be applied to threads to help prevent oil leakage. TIGHTEN plug securely.

18. Press bearing (item #25) onto worm and into worm gear housing. NOTE: Be sure thick shoulder of bearings outer race Iside with manufacturer's name and num ber) is out, away from worm threads.

Place gasket (item #43) onto spur gear housing (item #16). Secure spur gear housing to worm gear housing using four capscrews (item #33). Torque capscrews to 7 ft-lbs. (9.4 Nm) each.

Mount motor (item #51) to spur gear housing (item #16) using three lockwash ers and nuts (items #39 & #41). Attach solenoid cables to motor terminals. Tighten all nuts securely.

Page 20

19. Place snap ring (item #65) over end of worm shaft (item #23) and set into snap ring groove. Insert key (item #19) into keyway of worm shaft. Place thrust washer (item #68) over each end of spur gear shaft (item #21). Set spur gear shaft assembly into bearing of spur gear housing. Slide gear (item #12) and(item #68) thrust washer over end of worm shaft (item #23).

Insert pins (item #57) into cover (item #9 ). Place gasket (item #44) onto cover. Attach cover and gasket to spur gear housing using twelve capscrews (item #28). Torque capscrews to 8 ft. lb. (10.8 Nm.) each. Insert plug (item #54) into bottom of spur gear housing. Permatex may be applied to threads to help prevent oil leakage.

Remove reducer and ﬁ tting (items #50 & #53) from top of spur gear housing. Pour 1/ 2 pint of SAE 20 weight motor oil into spur gear box. Replace reducer and ﬁ tting into top of spur gear housing. Tighten reducer and ﬁ tting securely .

20. Attach mounting angles (items #4 & #5) using six capscrews (item #32) with lock washers and capscrews (items #35 & #31) . Torque capscrews to 34 ft. lb. (46 Nm.) each. Insert plug (item #54) into bot- tom of gear housing. Permatex may be applied to threads to help prevent leak- age.

Pour 3/4 pint of EP 140 gear oil into housing through hole in top of housing. Insert relief ﬁ tting (item #50) into reducer (item #53) . Reducer should then be placed into hole on top of gear housing. Tighten ﬁ tting and reducer securely.

Page 21

DIMENSIONAL DRAWING

DC-200 SERIES

6,4

3.72

CONNECT POWER CABLE

BATTERY TERMINAL HERE

FROM POSITIVE (+)

6.22

.25

94,4

157,9

1.12

28,6

3.47

7.03

88,2

178,6

CONNECT GROUND CABLE

GROUND TERMINAL TO

BATTERY TERMINAL.

NEGATIVE

FROM MOTOR ISOLATED

INCHES

WINCH

MODEL

333,3

13.12

8.94

227,0

287,3

11.31

7.78

197,6

DC-200

8.12

11.44

6.31

5.28

DCY-200

206,3

290,5

160,3

134,1

2.50

6.75

63,5

171,4

4.56

2.50

63,5

3.62

92,0

6.41

3.50

DIA.

88,9

162,8

7.25

DIA.

184,2

1.37

34,9

2.50

63,5

36.00

914,4

115,8

2.12

53,9

POSITION

CLUTCH AT

DIS-ENGAGED

2.19

55,6

DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS

2.50

63,5

.69

17,5

Page 22

DC-200 SERIES

EXPLODED DRAWING

SEE PAGE 23 FOR

COMPONENT BREAKDOWN

SEE PAGE 22 FOR OPTIONAL WORM BRAKE PARTS LIST

Page 23

PARTS LIST

DC-200 SERIES

6NCX1/ 2 HX SOCK HD

/4- 20NCX7/ 8 LG. HEX HD,

083 CA P-BR G 48 4 450016 K EY- BARTH,5/ 16X 15/16L,PWD MET, MSG7

334161 GEA R- RH,SL, 56 1 468018 PIP E PLUG -HX S OC HD

1 302811 AN GLE-MOD. " Y" 45 1 442205 GA SKET

1 296903 SOLEN OI D ASSY- 24VDC 42 2 330010 DRAG BRA KE

1 1 276056 A SSY- SHIFTER,HD200&HDG350 40 3 418154 WA SHER

2 1 296902 S OLENOID AS SY-12V DC 41 10 418177 LOCKWAS HER

ITEM NO. QTY. PART NO. DESCRIPTION ITEM NO. QTY. PART NO. DESCRIPTION

4 1 302808 A NGLE- STD 44 1 442185 GA SKET

3 1 282001 S WITCH A SSY 43 2 442184 GA SKET

1 302810 AN GLE-MOD. " Y" 47 2 450006 K EY- BARTH,5/ 16X1 7/8LG, W/V-GR V JA W

8 1 328134 C OV ER-GEAR HSG 50 2 456008 RELIEF F IT-1/ 8-27PFT,BALL CHECK ,Z/P

6 1 316

7 1 324160 J AW CLUTCH 49 1 456001 FITTING- LUBE

5 1 302809 A NGLE- STD 46 NOT USED

1 332007 DRUM- MOD "Y" 52 NO T USED

9 1 328106 C OV ER-SPUR GH 51 1 262037 12V , ELECTRIC MOTOR

10 1 332105 DRUM-STD 262036 24V, ELECTRIC MOTOR

11 1 334001 GEAR-I DLER 53 2 468002 REDUCER

14 1

13 NOT USED 55 2 468017 P IPE P LUG - HEX SOC HD

12 1 334003 GEAR 54 1 468011 P IPE P LUG - SQ HD

16 1 338203 HS G-SPUR GR 58 1 470033 SP IROL P IN

15 1 336010 HA NDLE- CLUTCH S HIF 57 2 470001 P IN

19 1 342023 KEY- SQ ENDS, 3/16X3/16X1/2 LG, C1018 61 1 482013 RUBBER BOOT

18 1 338273 HO USI NG-GEAR,MOD. 60 1 472013 PLUG

17 1 338208 CLUTCH HSG-RAM-LO K 59 1 472012 PLUG

9 SHAF T- DRUM,200,4 KEYSEATS, 4140CF HT 64 1 486023 SHAFT, SEAL

1 357481 SHA FT-DRUM - MOD. "Y" 65 1 490003 SNA P RIN G

1 368019 WORM-R.H. 46:1 67 1 494053 SP RI NG

22 1 35747

21 1 356901 SHAFT- SPUR GH,3/ 4X2 13/16LG P URCH C 63 1 486017 O IL SEA L

20 1 342033 KEY- SQ ENDS, 3/16X3/16X1- 7/16LG,SOF T 62 1 486009 OIL S EAL

23 1 368001 WORM-R.H. 60:1 66 2 494002 SPRIN G

26 2 412003 BUS HING 70 1 518015 THRUST WA SHER

27 2 412045 BUS HING 71 NOT US ED

25 2 402002 BEARIN G - BALL 69 1 518014 THR UST WASHER

24 2 402001 BEARIN G - NEEDLE 68 3 518002 THR UST WASHER

28 12 414038 CAPS CREW- 1/4-20NCX 3/4,HX HD,GR- 5,Z/P

29 10 414045 CAPS CREW- 1

30 3 414059 CAP SC REW-1/4-20NC X1LG GR- 5 HXHD Z/P FOR GA SK ET KIT & SEAL KI T

31 1 414279 CAP SC REW-3/8-16NC X3/ 4 LG,HXHD,GR- 5 ORDER P/ N 246039

32 6 414282 CAP SC REW-3/8-16NC X1 1/ 4LG,HXHD GR-5

33 4 414845 CAP SC REW-1/4-20NC X1, HXSOCHD,N YLOK

34 2 414856 CAP SC REW-1/4-20NC X3/ 4LG,HXSOCHD Z/P

35 1 414912 CAP SC REW-3/8-16NC X5/ 8LG,HXSOCHD

36 N OT USED

39 3 418040 NUT-3/8- 24NF HEX REG ZI NC PLATED

37 1 416030 SS- 1/4-20N CX3/8, HXSO C,F. DOG,N YL,Z/ P

38 1 416059 SETSCREW3/8-1

Page 24

DC-200 BRAKE

EXPLODED DRAWING

Item No Qty Part No. Description

101 1 306034 SPRING -FLA T 102 1 314008 CAM PLATE 103 1 328128 COVER 104 1 338007 HOUSING -BRAKE 105 1 340002 HUB 106 1 342027 KEY 107 1 352022 RETAINER PLATE 108 1 368021 WORM-R.H. 60:1 RATIO 109 1 368022 WORMrR.H. 46:1 RATIO 110 2 400003 BALL 111 2 414021 CAPSCREW 1/4-20NCx 1 LG. HX.HD. GR.5 NY -LOK HVY.PATC 112 4 414039 CAPSCREW 1/4 20N Cx 1 LG. HX.HD. GR.5 113 1 414228 CAPSCREW 3/8-16NCx-1/2 LG. HX.HD. ALL-THRD. 114 4 414821 CAPSCREW 1/4-20 NCx7/8 LG. BUTTON HD. 115 1 418036 NUT 3/8-ISNC HX.JAM 116 6 418154 WASHER-FLAT l/4 ALUM. 117 1 442189 GASKET 118 1 474001 PLATE-THRUST 119 1 486069 THREAD SEAL 120 1 494007 SPRING

Page 25

)

Solenoid Assembly Parts

278027 - 12V 278028 - 24V

Item Oty. No. Req'd Par t N o. Description

1 1 280009 Cable-Bol t Ass' 23289077 Wire Ass' 3 1 289091 Wire Ass' 4 2 364001 Stra 5 2 364002 Stra 6 1 408035 Solenoid Bracket 7 2 416216 Screw 8 2 416227 Screw

9441Em4Nut 10 2 410022 Nu t 1/4 - 18N C Hx. Re 11 2 418140 Flat Washer #10 12 1 418163 Lockwasher 5/ 16 M ed Sect 13 1 418164 Lockwasher 5/ 16 Inter nal 14 1 418165 Lockwasher 5/ 16 Exter nal 15 1 43 16 2 440071 Term inal - Tab 17 2 440110 Solen oid- 12V 18 1 472071 Cover 19 1 482029 Cover-Connector 20 4 530106 Cover-Terminal

013 Femal e Con nector

Page 26

TEST PROCEDURE FOR SOLENOIDS

Steps to follow when testing current ﬂ ow through DC solenoids. It should be noted that when testing a 12 volt or 24 volt solenoid, the DC motor and battery must be of the same voltage. To test the solenoids: (See Figure 1).

1. Securely clamp a motor to a bench or work surface.

2. Attach a #6 gauge jumper wire from “A” terminal on the motor to one of the ﬁ eld termi- nals on the motor, (F-2).

3. Attach the other motor ﬁ eld terminal (F-1) to one of the side terminals of the solenoid.

4. Ground the solenoid to the motor with a wire as shown.

5. Attach positive (+) battery wire to the opposite side terminal of solenoid. Ground the negative (-) battery wire to the motor housing.

6. Touch “hot” wire, from the positive battery terminal, to small terminal of the solenoid.

7. The motor should now be running if the solenoid is good. If not, make sure the motor will run directly from the battery. (See motor test procedure page 20).

8. To test the upper contacts use the same hookup except use the top terminals. (See Figure 2). When hooked up as shown in Figure 2, motor should start running.

When the “hot” wire is touched to the small terminal the motor will stop operating. The top terminals are normally closed; ie: connected, and the side terminals open, or

not connected. When the solenoid operates, the top terminals are disconnected and the side terminals are connected.

Take care not to bring hot wires into contact with ground in order to prevent electrical arcing.

BATTERY

(TOP TERMINALS)

SIDE SIDE

(SMALL)

SOLENOID

GROUND WIRE(-) FROM SOLENOID TO MOTOR

FIGURE-1

ISOLATED GROUND

TERMINAL

MOTOR

(TOP TERMINALS)

SIDESIDE

(SMALL)

SOLENOID

GROUND WIRE(-) FROM SOLENOID TO MOTOR

BATTERY

ISOLATED GROUND

MOTOR

TERMINAL

FIGURE-2

Page 27

TEST PROCEDURE FOR MOTOR

The Ramsey Winch motor is a (4 pole-4 coil)series wound 12 volt or 24 volt DC motor. The 4 pole, 4 coil feature provides high torque at low speeds.

To test the motor to determine if it is functioning properly, ﬁ rst securely fasten the motor to a bench or work surface so it will not jump or move around during test procedure (the starting torque of motor is high).

1. Connect a jumper wire (at least a number 6 wire)from F-1 to “A” motor terminals (See Figure 1)

2. Attach a wire (at least a number 6 wire) from positive (+) battery terminal to F-2 motor ter minal. Ground negative (-) battery terminal to motor isolated ground terminal (See Figure 1). Motor should now run.

To reverse the direction of rotation:

1. Attach jumper wire from F-2 to “A” motor terminals (See Figure 2).

2. Attach wire from positive {+) battery terminal to F-1 motor terminal. Ground negative (-) battery terminal to motor housing (See Figure 2).

NOTE: Always attach battery wire solidly to motor terminals. Make and break the connection of the negative (-) battery terminal at the motor housing. This avoids burning the motor terminals. CAUTION: Do not run the motor for a long period of time in fashion mentioned above, because the motor could become damaged.

The motor running idle on the bench will draw 55 amperes and must run free and easy. If the ampere draw is more than 60 amps and the motor runs rough or has a strange sound, it should be replaced. With the motor attached in place on a winch (less cable on drum) the ampere draw should be approximately 65 to 70 amps. If after following the procedure outlined, the test on the winch signiﬁ cantly exceeds 70 amperes refer to your Owners Manual for trouble shooting suggestions on the mechanical portion of the winch.

See Figure 3 for the solenoids connection to the motor and the battery.

BATTERY

SOLENOIDS TO MOTOR CONNECTIONS

THE DASHED LINES ARE CURRENT'S PATH IN FORWARD ROTATION. SOLID LINES ARE CURRENT'S PATH AT ALL TIMES. NOTE:

DIRECTION OF MOTOR ROTATION DEPENDS ON WHICH SMALL TERMINAL OF EITHER SOLENOID IS CONNECTED TO BATTERY'S POSITVE TERMINAL.

ISOLATED GROUND TERMINAL

ISOLATED GROUND

FIGURE-1

MOTOR-CLOCKWISE ROTATION

BATTERY

ISOLATED GROUND

CCW

FIGURE-2

MOTOR-COUNTER CLOCKWISE ROTATION

BATTERY

SOLENOIDS TO MOTOR CONNECTIONS

THE DASHED LINES ARE CURRENT'S PATH IN REVERSE

ROTATION. SOLID LINES ARE CURRENT'S PATH AT ALL TIMES.

FIGURE-3

ISOLATED GROUND TERMINAL

Page 28

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 im-

prove 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 ﬁ eld 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 ﬁ eld representa- tive. 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

RAMSEY WINCH COMPANY

Post Ofﬁ ce Box 581510 Tulsa, Oklahoma 74158-1510

Telephone: (918) 438-2760 FAX: (918) 438-6688

912408-1013-Z