Ramsey DC-7, DC-7B User Manual

OPERATING,SERVICE, AND MAINTENANCE

MANUAL

MODELS DC•7/DC•7B SERIES

INDUSTRIAL LOW-MOUNT WINCHES

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

TABLE OF CONTENTS

INTRODUCTION ....................................................... 1

WARRANTY INFORMATION

SPECIFICATION

T ECHNIQ UES OF O PERATIO N

....................................................... 1

....................................................... 2

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

WINCH MAINT ENANCE

WINCH MOUNTING

ELECT RICAL CON NECTIO NS

CABLE INSTALLATION

TROUBLE SHOOTING GU IDE

....................................................... 3

....................................................... 4

....................................................... 4-5

INSTRUCTI ONS FOR OVERHAUL OF

RAMSEY M ODEL DC-7/DC-7B SERIES WINCHES

DISASSEMBLY REASSEMBLY

DIMENSIONAL DRAWING

PAR TS LIST AND PARTS DRAWING

SOL ENOID AND SW ITCH ASSEM BL Y PARTS LIST

T EST PROCEDUR E FOR SO L ENOID

T EST PROCEDUR E FOR M OTO R

MOTOR ASSEM BLY PARTS L IST

....................................................... 6-9

....................................................... 9-11

....................................................... 12-13

....................................................... 14-17

....................................................... 18

....................................................... 19

....................................................... 20

....................................................... 21

LIMITED WARRANTY ....................................................... 22

RAMSEY ELECTRICAL WINCH MODEL DC-7 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 (Lbs.)................................................................................................3,000

Total Gear Reduction: All Models...........................................................................................298:1

Weight: DC-7 ......................................................................................................70 Lbs.(32 Kgs.)

DCX-7 ....................................................................................................75 Lbs. ( 34 K g

DC-78 ....................................................................................................60 Lbs. (27 Kgs.)

DCX-78 ..................................................................................................65 Lbs. (29 Kgs.)

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

Layer of Cable 2 3 4 5** Rated Line P u ll Lbs. 2,600 2,300 2,000 1,800 per layer Kgs. 1,170 990 900 810 *DC-7/78 Drum Cable Ft 20 35 50 70 capacity per layer M 6 10 15 21 *DCX-7/78 Drum Cable capacit y p e r layer M 12 19 28 38

LIN E SPEED FPM FPM FPM FPM

ALL MODELS 24

(Kgs.)................................................................................................1,360

1 3,000 1,350

VOLTS (MPM) AMPS (MPM)

12 17 80 12 110 8 150 7 180

NO LOAD 1000# LOA D 2000# LOA D 3000# LOAD

40 (3.7).60 (2.4).75 (2.0)

(5.2)

40 65 95 125

(MPM) AMPS (MPM) AMPS

AMP

s.)

*These speciﬁ cations are based on recommended 1/4” diameter extra improved plow steel wire rope. **5th Layer does not conform to SAE J706

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

DUTY CYCLE

Winch duty cycles are shown below:

MINUTES

180

270 360

AMPS

12 V 24 V

MINUTES

90 120 160 190

AMPS

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 pile up 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.

WARNINGS:

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.

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 housing or clutch operating linkage. Any good grade of moly-disulﬁ de containing grease is accept- able.

2. 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.

3. Check the torque setting of the oil cooled worm brake. Make any adjustments required, fol lowing the procedure described in ADJUSTING THE OIL COOLED WORM BRAKE in the Owner’s Manual.

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.

C. ANNUALL Y

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 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.

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-7/DC-78 Series Winches are furnished with recommended mounting angles. Model DC-7 Winch is furnished with 1/4 x 2 x 2 high strength steel angles. Model DC78 Winch is furnished with 3/16 x 1-1/2 x 2 high strength steel angle.

ELECTRICAL CONNECTIONS

See dimensional drawings on pages 12 & 13. 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 BAT TERY POST. (SEE DIAGRAM BELOW)

SEE ILLUSTRATION

BELOW

NEGATIVE BATTERY POST

ISOLATED GROUND TERMINAL

GROUND CABLE

JUMPER WIRE(#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 applica-

Isolated Motor Ground

tions a jumper wire (#440315) is required to ground the solenoid assembly.

CABLE INSTALLATION

1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of cable, opposite hook, with plastic or similar tape to prevent fraying.

2. Insert the end of cable, opposite hook end, into the 21/64” 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.

TROUBLE SHOOTING GUIDE

CONDITION POSSIBLE CAUSE CORRECTION

OIL LEAKS FROM HOUSING. 1. Seal damaged or worn. 1. Replace seal.

2. Too much oil. 2. Drain excess oil. Refer to TECHNIQU ES OF OPERATION

3. Damaged gasket. 3. Replace gasket.

MOTOR RU NS IN ONE DIRECTION 1. Inoperative solenoid or stuck solenoid. 1. Jar solenoid to free contacts. Check by applying ONLY. volts to coil terminal (it should make an audib l e

click when

2. Remove switch plug from hood.

2. Inoperative switch. Raise connector cover on hood and with screw driver, short the bottom two pins. Solenoid should click. Short the two left hand pins. The other solenoid should operate. If both solenoids operate check for a broken wire in switch cable.

energized). (See Page 19)

3. Broken wire or bad connection 3. Check for loose connection on s connector.

MOTOR RU NS, BUT DRUM DOES 1. Sheared drum shaft key. 1-3. Dis-assemble winch to NOT TURN. determine cause and repair.

2. Stripped bronze gear.

3. Parted shaft.

MOTOR RU NS EXTREMELY HOT. 1. Long period of operation.

M OTOR RUNS, BU T WITH INSUFFI CIENT POWER, OR WITH LOW LINE SPEED.

MOTOR WILL NOT OPERATE. 1. Inoperative solenoid or stuck solenoid.

2. In sufficient battery .

3. Electrical cables from battery to winch too small.

4. Bad electrical

5. Insufficient charging system 5. Replace with larger system.

1. Cooling-off periods are essential to prevent over

heating.

2. Check battery terminal voltage under load. If 10 volts or less, replace or parallel another battery to it at motor terminal.

3. Must be #2 Ga. wire for batte ry to winch too small.

attery to winch. Use larger than #2 Ga. for distances

greater than 15 feet

4. Check all connections for looseness or corrosion; Ti

hten, clean and grease.

1. Jar solenoid to free contacts. Check by applying 12

volts to coil terminal (it should make an audible click when ener

ized).

witch and switch

2. Inoperative switch.

3. In o p e rati ve motor.

4. Loose connections.

2. Re-move switch plug from hood. Raise connector

cover on hood and with a screw driver, short the bottom two pins. Solenoid should click. Short the two left pins.

The other solenoid 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. (See Page 20)

4. Tighten connections on bottom side of hood and on

motor.

INSTRUCTIONS FOR OVERHAUL OF RAMSEY

MODEL DC-7/DC-7B SERIES WINCHES

DISASSEMBLY

1. Drain oil from worm gear housing by removing (item #51) plug from bottom of gear housing. Remove relief ﬁ tting and reducer (items #46 & #54) from top of gear housing. Remove winch from mount ing angles (items #6 & #7) by removing hardware shown (items #34 & #40). NOTE: DC-7B WINCH SHOWN. See Pg. 14 & 15 for mounting brackets and hardware for DC-7 winch.

2. Drain oil from spur gear box by removing (item #53) plug,from bottom of spur gear box. Remove cover and gasket (items #10 & #43) from spur gear housing by unscrew ing twelve cap screws (item #32). Slide gear (item #14) from end of worm shaft (item #26). Remove spur gear shaft (item #25), with gears attached. Check bearings (item #27) and thrust washers (item #61) for signs of wear, replace if necessary. Remove old bearings and press new bearings into place. Remove solenoid assembly (item #1) from winch as follows: Disconnect solenoid ca bles from motor (item #47). Make note of which terminals cables are attached to. Re move solenoid cover from solenoid mounting bracket by unscrewing two solenoid cover mounting screws. Solenoid mounting bracket may then be removed from winch by un screwing two soc. hd. screws attaching solenoid bracket to gear housing of winch. SEE SOLENOID ASS’Y. PARTS LIST, Pg.18

3. Remove key (item #20) and snap ring (item #60) from worm shaft. Remove motor (item #47) from spur gear housing (item #18) by removing three nuts and lockwashers (items #38 & #41). Uns crew four capscrews (item #35) to remove spur gear box (item #18) and gasket (item #42) from gear housing. Replace lip seals (items #57 & #59) by pressing old seals from spur gear hous ing and pressing new seals into place.

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