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