Ramsey Electronics DCY200 Operating instructions

RAMSEY
ELECTRIC WINCH
MODEL DCY/DC200
FITTING & OPERATING INSTRUCTIONS
Manual Part No. 10928 / 19.12.18
PART NO - 3561 / 3560

GUIDE TO SAFE WINCHING..............................................................................................3
WARNING ...........................................................................................................................4
INTRODUCTION.................................................................................................................4
WINCH RATING..................................................................................................................4
EXAMPLE............................................................................................................................4
FITTING INSTRUCTIONS...................................................................................................5
TYPES OF WINCH MOUNTING .........................................................................................5
BEHIND THE CAB...........................................................................................................5
Flush with Vehicle Deck using bracket part no. BM0001..............................................5
Above Deck Mounting...................................................................................................6
Front Mounting .............................................................................................................7
LABELS...............................................................................................................................7
WIRING ...............................................................................................................................7
WANDERLEAD REMOTE SOCKET................................................................................8
EMERGENCY STOP .....................................................................................................10
LOAD LIMITING SWITCHES.........................................................................................10
TESTING...........................................................................................................................11
TO OPERATE WINCH.......................................................................................................11
FREE SPOOLING..........................................................................................................12
CAPACITIES .....................................................................................................................12
SERVICE/MAINTENANCE................................................................................................12
REGULAR MONTHLY MAINTENANCE ........................................................................12
Yearly maintenance....................................................................................................12
OIL SPEC...................................................................................................................13
SPARES.....................................................................................................................13
CARE OF THE WIRE ROPE.............................................................................................13
WIRE ROPES ARE NOT COVERED BY WARRANTY..................................................13
FITTING WIRE ROPE....................................................................................................13
TROUBLE SHOOTING TIPS.............................................................................................15
WINCH PARTS LIST.........................................................................................................18
SOLENOID ASSEMBLY PARTS.......................................................................................19
TEST PROCEDURE FOR SOLENOIDS ...........................................................................20
TEST PROCEDURE FOR MOTOR...................................................................................21
INSTRUCTIONS FOR OVERHAUL OF RAMSEY.............................................................22
MODEL DC-200 SERIES RAM-LOK .................................................................................22
DIS-ASSEMBLY.............................................................................................................22
RE-ASSEMBLY..............................................................................................................26
WARRANTY......................................................................................................................29
APPENDIX.........................................................................................................................30
BATTERIES...................................................................................................................30
2

GUIDE TO SAFE WINCHING
The following safety precautions must be observed at all times whilst using the winch.
Keep yourself and others at a safe distance to the side of the wire rope when pulling under
load.
Never step over, stand near or guide a rope under tension.
Always use heavy-duty gloves when handling the wire rope to protect against cuts or
possible burns.
Take care of the wire rope. Check regularly for signs of wear in the form of broken strands
or severe kinks along its length. If there are more than 10 strands broken in any one inch
of the rope's length, then it will be significantly weakened and must therefore be replaced.
Wear and tear can be prevented by regular application of rope dressing available in
aerosol form from your winch supplier. Oil and grease should never be used.
Always ensure that the rope is rewound neatly back onto the drum after use. If the rope is
tensioned whilst unevenly wound, then loose coils can become trapped and badly
damaged.
Do not drive the vehicle to pull a load on the winch wire rope, e.g. as a tow rope. Any
resulting shock load could break the rope or damage the winch.
If the winch is being operated at maximum capacity, drape a heavy blanket or coat over
the wire rope, halfway along its length. The blanket will reduce the speed of a snapped
rope.
When recovering a vehicle, the winch hook should be attached to the towing hitch, if
available, or to a strap or chain around a chassis leg or cross member. NEVER anchor the
winch hook onto bumpers, or shipping/transit anchorage.
Do not allow the load to 'snatch' during a pull, as this can momentarily double, or even
treble the load on the rope.
Try to position either your vehicle or the anchor point to ensure as straight a pull as
possible. Use a snatch block if it is necessary to turn any corners with the rope.
When attaching the hook to the load, always double check that the hook is secure and the
safety catch is fully closed. Remember that if the hook breaks away under tension, serious
injury can result as the hook will travel through the air at speed.
A minimum of five wraps of rope around the drum is necessary to support the rated load.
The rope to drum securing clamp is not designed to hold a load.
3

Never attempt to disengage the free spool clutch when winch is under load.
WARNING
These winches are not intended for use in the lifting or moving of personnel.
INTRODUCTION
PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLATION OR OPERATION
OF THE WINCH.
Ramsey Winches are widely used for commercial purposes throughout the world. As the
new owner/operator of a RAMSEY WINCH, it is important that you read and digest the
information contained in this Handbook. The winch is of the highest quality and has been
designed to give a robust and efficient service for many years if care and attention are
given at all times to correct, safe operation and maintenance.
Do not underestimate the potential danger in winching operations. Neither should you fear
them. Do learn the basic dangers and avoid them. Respect for your winch and common
sense in its operation, will ensure complete safety and reliability.
WINCH RATING
The Ramsey Winch rating on this model refers to its maximum rated line pull, measured as
the force being applied to the winch in a horizontal plane. As in the case of all winches,
this refers to the first layer of rope on the drum.
In most cases, when the winch is being used, there is no way of accurately determining
the exact pull being applied. It is important, however, to try and establish that it is within
the working capacity of both the winch and wire rope and this can be done by considering
the following formulae which applies for gradients up to an angle of 45°. For wheeled
vehicles, the pull required to move the load equals:
W
+ (W x angle of gradient).
25 60
Where W = load in tonnes and angle of gradient is in degrees.
EXAMPLE
If W, the load of the vehicle is 4 tonne and is being pulled up skids, which form a gradient
of 18°, the force on the rope is:
4+ (4 x 18) = 0.16 + 1.2 = 1.36 tonne.
25 60
Remember the winch pulling capacity reduces as the number of layers of wire rope
increase on the drum.
4

5
If it is necessary to work beyond the limits of either the winch or wire rope, it is essential
that a snatch block be employed which will enable the line pull to be nearly doubled.
If you should have any queries regarding the maximum load applied in a particular
application, please do not hesitate to contact us and we will be pleased to offer our
assistance.
FITTING INSTRUCTIONS
The Ramsey Winch has a world-wide reputation for toughness and reliability. The design
of this long established product has been well proven over the years for many applications.
To ensure the best service from your Ramsey Winch it is most important to follow these
instructions for its fitting and subsequent operation.
Irrespective of how the winch is mounted it is important that adequate provision is made so
that the load is transmitted into the body of the vehicle and then into the chassis.
TYPES OF WINCH MOUNTING
BEHIND THE CAB
Flush with Vehicle Deck using bracket part no. BM0001
Fit two channel or angle members between the first and second cross bearer spaced at
635mm (25"), the mounting bracket width. If fitting to a body with timber deck it may be
necessary to raise mounting height and the following method is suggested.
Weld or bolt 50mm (2" x 2") angle sections to the top of the channel members. Also use
this method when it is necessary to clear gear linkage or other chassis protrusions.
Using the mounting bracket as a jig, drill three holes 11mm (7/16") diameter each side into
the channel or angle members. Remove mounting bracket and fit this to the winch with
eight 3/8" diameter U.N.C. 20mm cap head screws supplied with kit.
5

Above Deck Mounting
There are two options of brackets available when installing the winch above deck. Fit to
channels or angles as per the flush type and bolt through floor.
6

Front Mounting
When fitting the winch to the front of the vehicle it is essential that the chassis will take the
loadings applied. In some cases it may be necessary for the chassis to be strengthened
e.g. 3.5 tonne GVW vehicles and we would recommend that the winch
mounting and chassis should be capable of taking loads of 3500kg. For further advice
please contact the chassis manufacturer or dealer. For heavy chassis the winch can
usually be mounted by flitch plates direct to the main frame of vehicle (never weld to
chassis or drill top or bottom flanges, without the manufacturers approval).
LABELS
WIRING
ENSURE THAT CORRECT VOLTAGE WINCH IS FITTED TO THE CHASSIS. IF IN
DOUBT, CONTACT THE CHASSIS MANUFACTURER.
The power feed to the winch must be capable of carrying 300 amps for 12v units and 175
amps for 24v units. The recommended cable for 12v is 315 strands of 0.40mm diameter
per strand and for 24v is 196 strands of 0.40mm diameter per strand. This cable should be
as short as possible to run from the batteries to winch power connection (see diagram
below).
7

A high amperage isolator switch must be fitted (supplied on request), in a prominent
position. The earth return is made through the winch mounting then back into the chassis
of the vehicle.
Whenever possible, earth the winch back to the battery. If this is impractical and earth is to
the chassis, it may be necessary to upgrade the vehicle earth strap from battery to the
chassis.
If earthed to chassis, ensure the connectors are clean and free of paint.
IF IN DOUBT, FIT EARTH RETURN SIZE AS RECOMMENDED FOR POWER FEED.
We would recommend that a high amperage fuse is always fitted in the circuit. These can
be purchased separately from BHW Group Ltd. Please quote the following part numbers.
FU0020 300 amp fuse (for 12v winch).
FU0040 200 amp fuse (for 24v winch).
FU0050 Holder for above fuses.
(See wiring diagram above).
WANDERLEAD REMOTE SOCKET
Position female connector to accept wanderlead at convenient point and to avoid damage
and water spray. Connect a 3 core 5 amp waterproof cable and secure this to avoid
chaffing and route to winch position. Fit a male connector to plug into winch socket. Silicon
waterproof sealant is recommended around all electrical connectors. There are kits
8

available for both single and double rear sockets. Part numbers SC0125 and SC0150.
(See wiring diagram below).
9

EMERGENCY STOP
All electric winches must be fitted with an emergency stop/isolator switch within the circuit
(as shown in diagram). This should be easily accessible and clearly marked. The
operators should familiarise themselves with this switch before winch operation.
ON NO ACCOUNT WIRE DIRECTLY INTO WINCH.
ISOLATOR SWITCH MUST BE TURNED OFF WHEN WINCH IS NOT BEING USED.
Always keep the length of the feed wire and earth return to a minimum to avoid voltage
drop.
In some circumstances when the vehicle is involved in constant use with only short
distances between winching operation, it will be necessary to fit an additional heavy duty
battery wired in parallel with the vehicle battery.
Keep this as close to the winch as possible.
It is also advisable in these circumstances to have the vehicle fitted with a heavy duty
charging system and batteries.
The above comments also apply to vehicles operating with maximum loads imposed on
the winch.
LOAD LIMITING SWITCHES
Electric load limiting switches can be supplied as an option on this model.
If fitted, it is important to ensure that the winch is fitted in the correct rotation. Whilst the
limit switch is calibrated to the approximate safe working load required by the customer at
point of order, fine adjustment is necessary after installation.
(See wiring diagram below).
10

This is supplied complete with a length of positive battery supply cable. Under no
circumstances should this length of cable with shunt fitted be altered, as this will affect the
functioning of the overload switch.
TESTING
After the installation is complete, a proof load test of 125% of the rated load should be
carried out before the winch goes into service.
TO OPERATE WINCH
Turn on isolator switch, plug in wanderlead control. The winch can be powered both in and
out. The load is automatically held safely when control button is released.
The best way to become acquainted with how you winch operates is to make test runs.
Plan you tests in advance. Remember that you hear your winch as well as see it operate.
Come to recognise the sounds of a light steady pull, heavy pull, and sounds caused by
load jerking or shifting. Gain confidence in operating your winch and its use will become
second nature to you.
The uneven spooling of wire rope whilst pulling a load, is not a problem, unless there is a
pile up of rope on one end of the drum. If this happens, reverse the winch to relieve the
tension on the rope and move your anchor point further to the centre of the load. After the
job is complete, you can unspool and rewind the wire rope neatly.
11

FREE SPOOLING
Ram-Lock Clutch
To release clutch, power out winch until tension is released from cable. Pull out handle on
side of casing and turn 90°. To re-engage, turn lever back to horizontal position. Turn drum
slowly by pulling out cable. The handle, which is spring-loaded, will automatically re-
engage. Ensure that handle is fully engaged before imposing load on winch.
Capacities
The Ramsey Winch is rated at 3630kg (8000lbs) and this refers to its safe working load,
measured as the force being applied to the winch in a horizontal place. As in the case of
all winches, this refers to the first layer of rope on the drum.
SERVICE/MAINTENANCE
REGULAR MONTHLY MAINTENANCE
Externally:
The winch should be kept clean in order to prevent any build up on corrosion on external
working parts.
Greasing of roller guides (if fitted) at grease points (one for each roller).
Also check for:
Rollers revolving
Slight or deep grooving
Excessive wear on rollers
NOTE:
If roller guides are worn excessively, wire rope life will be reduced and roller guides should
be replaced.
Check winch for external damage.
Check winch mounting for distortion and re-tighten mounting bolts if necessary.
Operate free spool clutch mechanism to ensure correct operation, giving full engagement
and disengagement.
All external-moving parts should be lubricated with lightweight oil.
Check oil level in gearbox and replenish with EP90 gear oil.
Yearly maintenance
In addition to the above maintenance change the oil in winch gearbox and spur box. Refill
to oil level plugs.
12

OIL SPEC
Spur gearbox
S.A.E. 20 (½ pint) 0.29 litres
Worm housing
E.P.90/140 (1 pint) 0.58 litres
Check tightness of mounting bolts and
electrical connections regularly.
SPARES
Should it become necessary to obtain
replacement parts, refer to list shown.
Please contact us quoting serial numbers
and model number.
BHW Group Ltd
reserve the right to change specification
without notice.
CARE OF THE WIRE ROPE
It is most important that the wire rope is inspected on a regular basis, for kinks, flat spots,
broken strands and other damage, and if necessary the damaged sections should be cut
away and the rope re hooked or completely replaced.
It is good practice to regularly use rope lubricant, obtainable from us if required, as this will
prevent rust and corrosion, which can seriously reduce its working life.
A good habit to form is that of rewinding the rope onto the winch drum after it has been
used, so that it is evenly layered. To do this, rewind keeping the rope under tension.
Normally the load can be applied by hand.
Under no circumstances wrap the wire rope around the load being recovered and then
attach the hook back on to the rope. This will result in serious rope damage or breakage.
Always employ a chain or webbing strap from the hook to the load.
WIRE ROPES ARE NOT COVERED BY WARRANTY.
FITTING WIRE ROPE
Unwind cable on floor behind vehicle; pass through roller and secure cable to the drum-
using setscrew provided. Operate winch, using wanderlead and wind on cable whilst
keeping it under tension, and layer the rope on as evenly as possible. The winch is now
ready for use.
13

14

TROUBLE SHOOTING TIPS
CONDITION POSSIBLE CAUSE CORRECTION
CLUTCH INOPERATIVE
OR BINDS UP. 1) Dry or rusted shaft. 2) Bent yoke or linkage. 1) Clean and lubricate. 2) Replace yoke or shaft
assembly.
3) Clutch jaws are in
contact. 3) See techniques of operation.
OIL LEAKS FROM
HOUSING 1) Seal damaged or worn. 1) Replace seal
2) Too much oil. 2) Drain excess oil. Refer to
techniques of
operation.
CABLE DRUM WILL NOT
FREE SPOOL. 1) Winch not mounted squarely, causing end
bearings to bind drum.
1) Check mounting, refer to
winch mounting Page 4
CABLE BIRD NESTS
WHEN CLUTCH IS
DISENGAGED.
1) Drag brake disc worn. 1) Replace discs.
MOTOR RUNS IN ONE
DIRECTION ONLY. 1) Inoperative solenoid or stuck solenoid. 1) Jar solenoid to free contacts. Check by applying 12volts to
coil
terminal (it should make an
audible click when energised).
2) Inoperative switch. 2) Disengage winch clutch or
remove armature lead.
Remove
switch plug from hood. 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.
3) Broken wire or bad
connection. 3) Check for loose connection on switch and switch connector.
MOTOR RUNS BUT
DRUM DOES NOT TURN. 1) Clutch not engaged. 2) Sheared drum shaft
key.
3) Stripped bronze gear.
4) Parted shaft.
1-4) If clutch engaged but
symptom
still exists, it will be necessary
to disassemble winch to
determine cause and repair.
15

TROUBLE SHOOTING (cont'd.)
CONDITION POSSIBLE CAUSE CORRECTION
MOTOR RUNS
EXTREMELY HOT 1) Long period of operation. 1) Cooling-off periods are essential to prevent over
heating.
MOTOR RUNS, BUT
WITH
INSUFFICIENT POWER
OR WITH
LOW LINE SPEED.
2) Insufficient battery. 2) Check battery terminal voltage
under load. If 10 volts or less,
replace or parallel another
battery to it at motor terminal.
3) Electrical cables from
battery to winch too
small.
3) Must be correct size and
capacity electrical cable for the
voltage
4) Bad electrical
connections. 4) Check all connections for looseness or corrosion;
Tighten, clean and grease.
5) Insufficient charging
system. 5) Replace with larger capacity charging system.
MOTOR WILL NOT
OPERATE 1) Isolator switch not turned on.
2) Fuse has blown.
3) Break in power lead or
extension socket.
4) Inoperative solenoid
or stuck solenoid.
1) Turn on isolator switch.
2) Replace fuse.
3) Repair or replace wiring.
4) Jar solenoid to free contacts.
Check by applying 12volts
to coil terminal (it should
make an audible click when
energised).
5) Inoperative switch. 5) Disengage winch 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 pins. The
other solenoid should operate.
If both solenoids operate,
check for a broken wire in
switch cable.
16

TROUBLE SHOOTING (cont'd.)
CONDITION POSSIBLE CAUSE CORRECTION
MOTOR WILL NOT
OPERATE 6) Inoperative motor. 6) If solenoids operate, check for voltage at armature post,
replace motor.
7) Loose connections. 7) Tighten connections on bottom
side of hood and on motor.
17

WINCH PARTS LIST
Item
No. Qty. Req'd Part No. Description Item No. Qty. Req'd Part No. Description
1 1 276028 Shifter Assembly* 19 1 342023 Key-Square
2 1 278027 Solenoid Assembly-12V 20 1 342033 Key-Square
278028 Solenoid Assemb!y-24V 21 1 356901 Shaft-Spur
3 1 282001 Switch Assembly 22 1 357479 Shaft-Drum-Std
4 1 302808
A
ngle (std) 1 357481 Shaft-Drum-Mod Y
1 302811
A
ngle (mod Y) 23 1 368001 Worm-R.H. – 60:1
5 1 302809
A
ngle (std) 1 368019 Worm-R.H. – 46:1
1 302810
A
ngle (mod Y) 24 3 402001 Bearing Needle
6 1 316083 Cap- Bearing 25 2 402002 Bearing Ball
7 1 324160 Jaw Clutch 26 4 412003 Bushing
8 1 328134 Cover-Worm Gear Hsg 27 1 412045 Bushing
9 1 328106 Cover-Spur Gear Hsg 28 22 414038 Capscrew 1/4 -20NC x 3/4 LG Hex HD z/p
GR5.
10 1 332007 Drum –Mod Y 29 4 414045 Capscrew 1/4 -20NC x 7/8 LG Hex HD
GR5.
1 332105 Drum-Std 30 3 414059 Capscrew 1/4 -20NC x 1 LG Hex HD z/p
11 1 334001 Idler Gear 31 1 414279 Capscrew 3/8 -16NC x 3/4 LG Hex HD
GR5.
12 2 334003 Gear 32 6 414282 Capscrew 3/8 -16NC x 1-1/4 LG Hex HD
z/p GR5.
13 1 334129 Pinion 33 4 414845 Capscrew 1/4 -20NC x 1 LG Soc Hd Nyloc
14 1 334161 Gear R.H. –60:1 34 2 414856 Capscrew 1/4 -20NC x 3/4 LG Soc Hd z/p
1 334163 Gear R.H. – 46:1 35 1 414912 Capscrew 3/8 -16NC x 5/8 LG Soc Hd
15 1 336010 Handle 36 1 416029 Setscrew 1/4 -20NC x 5/16 LG Soc Hd
16 1 338203 Housing-Spur Gear 37 1 416030 Setscrew 1/4 -20NC x 3/8 LG Soc Hd (Full
Dog Point)
17 1 338208 Housing-Clutch 38 1 416059 Setscrew 1/4 -20NC x 3/8 LG Soc Hd
18 1 338273 Housing-Gear 39 3 418040 Nut 3/8 – 2NF Hex Reg z/p
18

Item
No. Qty. Req'd Part No. Description Item No. Qty. Req'd Part No. Description
41 10 418177 Lockwasher 3/8 Med Sect
z/p 67 1 494053 Spring
42 2 438014 Drag Brake 68 3 518002 Thrust Washer
43 1 442184 Gasket 69 1 518014 Thrust Washer
44 1 442185 Gasket 70 2 518015 Thrust Washer
45 1 442205 Gasket 71 1 518018 Fibre Washer
46 1 450001 Key
47 2 450006 Key – Barth
48 4 450016 Key - Barth
49 1 456001 Lub Fitting
50 2 456008 Relief Fitting
51 1 458001 Motor-12V
1 458005 Motor- 24V
52 1 462015 O-Ring
53 2 468002 Reducer
54 2 468011 Pipe Plug Sq Hd
55 2 468017 Pipe Plug Soc Hd
56 1 468018 Pipe Plug Soc Hd
57 2 470001 Pin
58 1 470033 Spirol Pin
59 1 472012 Plug
60 1 472013 Plug
61 1 482013 Rubber Boot
62 1 486009 Oil Seal
63 1 486017 Oil Seal
64 1 486023 Oil Seal
65 1 490003 Snap Ring
66 2 494002 Spring
SOLENOID ASSEMBLY PARTS
Item
No. Qty. Req'd Part No. Description
1 1 289009 CABLE-BOLT ASSY
2 3 289077 WIRE ASSEMBLY
3 1 289091 WIRE ASSEMBLY
4 2 364001 STRAP
5 2 364002 STRAP
6 1 408035 SOLENOID BRACKET
7 2 416216 SCREW
8 2 416227 SCREW
9 4 418004 NUT
10 2 418022 NUT 5/16-18NC Hx REG
11 2 418140 FLAT WASHER 10
12 1 418153 LOCKWASHER 5/16
MED SECT
13 1 418154 LOCKWASHER 5/16
INTERNAL
14 1 418155 LOCK WASHER 5/16
EXTERNAL
15 1 430013 FEMALE CONNECTOR
16 2 440071 TERMINAL TAB
17 2 440110 SOLENOID 12V
2 440114 SOLENOID 24V
18 1 472010 COVER
19 1 482029 COVER CONNECTOR
20 4 530106 COVER TERMINAL
19

TEST PROCEDURE FOR SOLENOIDS
Steps to follow when testing current flow 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 jumper wire from (A) terminal on the
motor to one of the field terminals on the motor,
(F-2).
3. Attach the other motor field 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 the 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.
8. To test the upper contacts use the same hook-
up except use the top terminals.(See figure 2).
When the "hot" wire is touched to the small
terminal the motor will stop operating.
The top terminals are normally closed i.e.:
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.
20