Ramsey DCS-200 User Manual

OPERATING, SERVICE AND MAINTENANCE MANUAL

MODEL DCS-200

ELECTRIC INDUSTRIAL SPEED

REDUCER EZ ANCHOR

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

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TABLE OF CONTENTS

INTRODUCTION ………………………………………

WARRANTY INFORMATION ………………………………………

SPECIFIC ATION ………………………………………

WARNINGS ………………………………………

MAINTENANCE ………………………………………

TR O U BLE SHOO TI NG GU IDE ………………………………………

INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL DC-S200 SERIES

DISASSEMBLY & REASSEM BLY

………………………………………

DIM ENSIONAL DRAWIN G ………………………………………

PARTS LIST AND PART DR AWING ………………………………………

SOLENOID ………………………………………

LI M ITED WARRANTY ………………………………………

3-4

5-9

11-12

LA ST PAGE

RAMSEY ELECTRIC SPEED REDUCER MODEL DCS-200 SERIES

PLEASE READ THIS MANUAL CAREFULLY

This manual contains useful ideas in obtaining the most efﬁ cient operation from your Ramsey Speed Reducer, and safety procedures one needs to know before operation.

WARRANTY INFORMATION

Ramsey Speed Reducers are designed and built to exacting speciﬁ cations. Great care and skill go into every speed reducer we make. If the need should arise, warranty procedure is outlined on the back of this manual. If you have any problems with your speed reducer, please follow instructions for prompt service on all warranty claims. Refer to back page for limited warranty.

DUTY CYCLE

Speed reducer duty cycles is shown below:

MINUTES

180

270 360

AMPS

12V

WARNINGS

DO NOT EXCEED MAXIMUM RATINGS SHOWN IN THE TABLE. DO NOT USE SPEED REDUCER TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PERSONNEL. DISCONNECT THE REMOTE CONTROL SWITCH FROM SPEED REDUCER WHEN NOT IN USE. A RAMSEY PART NO. 282053 SAFETY ON-OFF SWITCH IN YOUR VEHICLE IS RECOMMENDED. IF A CABLE DRUM IS ADDED, A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM IS NECESSARY TO SUPPORT THE RATED LOAD. A CABLE CLAMP IS NOT

DESIGNED TO HOLD THE LOAD.

WINCH MAINTENANCE

Adhering to the following maintenance schedule will keep your speed reducer 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 location and repair.

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

B. MONTHLY

1. Check the speed reducer bolts. If any are missing, replace them and secure ly tighten any that are loose. Make sure to use only grade 5 bolts or better.

C. ANNUALLY

1. Drain the oil from the speed reducer annually or more often if used frequently.

2. Fill the speed reducer to the oil level plug with clean kerosene. Run the speed reducer a few minutes with no load in the reel in direction. Drain the kerosene from speed reducer.

3. Reﬁ ll the speed reducer 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.

ELECTRICAL CONNECTIONS

See dimensional drawing on page 10. 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 3/8” dia. bolt at motor. 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 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 18. 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. In applications where the chassis is non-grounded, a jumper wire (#440315) will be required between the winch and the motor ground. This ground is required to insure a sufﬁ cient ground to operate the solenoid assembly (see diagram below).

WINCH WILL NOT OPERATE UNLESS GROUND CABLE IS INSTALLED FROM THE ISOLATED GROUND TERMINAL T O THE NEGATIVE BATTERY POST. (SEE DIAGRAM BELOW)

SEE ILLUSTRATION

NEGATIVE BATTERY POST

Isolated Motor Ground

ISOLATED GROUND

TERMINAL

GROUND CABLE

For non-grounded chassis applications

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.

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

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.

TROUBLE SHOOTING GUIDE

CONDITION CORRECTIONPOSSIBLE CAUSE

OIL LEAKS FROM HOUSING

MOTOR RUNS IN ONE DIRECTION

1. Seal damaged or worn.

2. Too much oil

3. Damaged gasket

1. Inoperative solenoid or stuck solenoid.

2. Inoperative switch.

3. Broken wire or bad connection.

1. Replace seal.

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

3. Replace gasket.

1. Jar solenoid to free contacts. Check by applying 12 volts to coil terminal (it should make an audible click when energized).

2. Disengage speed reducer clutch or 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. Short the two left hand pins. The other solenoid should operate. If both solenoids operate check for a broken wire in switch cable.

3. Check for loose connection on

switch and switch connector.

MOTOR RUNS, BUT OUTPUT SHAFT DOES NOT TURN.

1. Sheared drum shaft key.

2. Stripped bronze gear.

3. Parted shaft.

1-3. It will be necessary to disassemble speed reducer to determine cause and repair.

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