Ramsey Winch DC 34,9 User manual

OM 914219-114-D
OPERATING, SERVICE AND
MAINTENANCE MANUAL
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND
OPERATION OF WINCH. SEE WARNINGS!
English (Original Instructions) . . . . . . . . . . . . . . . 1
Français (Traduction des instructions originales) . . 22
Deutsch (Übersetzung der Originalanleitung) . . . . . 42
Español(Traducción de las instrucciones originales).63
Ramsey Winch Company
P.O. Box 581510 - Tulsa, OK 74158-1510 USA
Phone: [phone] - Fax [phone]
Visit us at http://www.ramsey.com
INTENDED USE: VEHICLE RECOVERY AND PULLING OF LOADS
RAM-LOK®EQUIPPED
INDUSTRIAL LOW-MOUNT WINCHES
Ramsey Authorized Representative in the Community:
(Please contact for regultory inquiries only.)
Alura Group BV
P.O. Box 18626
2502 EP The Hague
The Netherlands
Tel: (31) (0) 70 362-4896
Fax: (31) (0) 70 346-7299
MODEL DC 34,9

4707 N. Mingo Tulsa, Oklahoma 74117 [phone]
EC DECLARATION OF CONFORMITY
as defined by Machinery Directive 2006/42/EC
Here with we declare that winch model DC34, 9 com-
plies with the following directive provided that the USER
complies with all responsibilities described in the Owner’s
Manual:
2006/42/EC
Applied harmonized standards:
EN 14492-1:2006
Power-Driven Winches
ISO 9001:2000
Quality Management Systems
Requirements
DÉCLARATION DE CONFORMITÉ EC
aux termes de la directive Machines 2006/42/EC
Nous déclarons par la présente que le modèle de treuil DC34,
9 est conforme à la directive suivante, sous réserve que
l’UTILISATEUR ait assumé toutes les responsabilités figurant
dans le manuel de l’utilisateur :
2006/42/EC
Normes harmonisées appliquées :
EN 14492-1:2006
Treuils motorisés
ISO 9001:2000
Systèmes de gestion de la qualité - Exigences
EC-KONFORMITÄTSERKLÄRUNG
gemäß Maschinenrichtlinie 2006/42/EC
Hiermit erklären wir, dass das Windenmodell DC34, 9 der
folgenden Richtlinie entspricht, sofern der BENUTZER
alle Anweisungen im Benutzerhandbuch befolgt:
2006/42/EC
Angewandte harmonisierte Normen:
EN 14492-1:2006
Kraftgetriebene Winden
ISO 9001:2000 Qualitätsmanagementsysteme -
Anforderungen
DECLARACIÓN EC DE CONFORMIDAD
según se define en la directiva de máquinas 2006/42/EC
Con la presente declaramos que el modelo de cabestrante
DC34, 9 se halla en conformidad con la siguiente directiva
siempre que el USUARIO cumpla todas las responsabi-
lidades descritas en el Manual del propietario:
2006/42/EC
Normas armonizadas aplicadas:
EN 14492-1:2006
Cabestrantes accionados mecánicamente
ISO 9001:2000
Requisitos de los Sistema de gestión de la calidad
Ramsey Authorized Representative in the Community / Ramsey Représentant autorisé dans la comuauté /
Ramsey Bevollmächtigter in der Europäischen Union / Ramsey Representante autorizado en la comunidad.
(Please contact for regulatory inquiries only. / Veuillez prendre contact uniquement pour des questions réglementaires.)
(Bitte nur bei Regulierungsfragen kontaktieren. / Póngase en contacto sólo por cuestiones de reglamentación.)
Alura Group BV
P.O. Box 18626
2502 EP The Hague
The Netherlands
Tel: (31) (0) 70 362-4896
Fax: (31) (0) 70 346-7299
Serial Number / Numéro de série/ Seriennummer/ Número de Serie:_____________________
Signature / Signature / Unterschrift / Firma:
Todd Brady
Engineering Manager / Directeur technique/ Technischer Leiter/ Director de ingeniería
Date / Date / Datum / Fecha:
05/03/11

USER’S RESPONSIBILITY FOR CE COMPLIANCE ……………………………………………………… 4
SPECIFICATIONS ……………………………………………………… 4
WARNINGS ……………………………………………………… 4
WINCH MOUNTING ……………………………………………………… 5
ROPE INSTALLATION ……………………………………………………… 5
TECHNIQUES OF OPERATION ……………………………………………………… 5
WINCH MAINTENANCE ……………………………………………………… 6
ELECTRICAL CONNECTIONS ……………………………………………………… 6
RATED LOAD LIMITER ADJUSTMENT ……………………………………………………… 6
END OF SERVICE MEASURES ……………………………………………………… 5
TROUBLE SHOOTING GUIDE ……………………………………………………… 7
INSTRUCTIONS FOR OVERHAUL DISASSEMBLY ……………………………………………………… 8-11
REASSEMBLY ……………………………………………………… 11-12
DIMENSIONAL DRAWING ……………………………………………………… 13
PARTS LIST AND PARTS DRAWING ……………………………………………………… 14-15
SOLENOID ASSEMBLY PARTS LIST ……………………………………………………… 16
TEST PROCEDURE FOR SOLENOID ……………………………………………………… 17
TEST PROCEDURE FOR MOTOR ……………………………………………………… 18
TABLE OF CONTENTS

4
* SPECIFICATIONS:
Ambient Temp Range -28C to 60C (-20F to 140F)
Noise Level . 80db
LAYER OF ROPE 1 2 3
Rated Line Pull Per Layer kN 34,9 28,9 24,9
lb 7,840 6,500 5,600
Cummulative Rope Capacity Per Layer (Long
Drum) m 7 16 28
ft 25 55 95
Cummulative Rope Capacity Per Layer (Short
Drum) m3 9 15
ft 10 30 50
Line Pull First Layer kN No Load 8,8 17,7 34,9
lb 2,000 4,000 7,840
* DC 34,9 & DCY 34,9 Line
Speed First Layer 12 V &
24V
MPM 4,3 2,1 1,5 1,7
FPM 14 7 5 3.5
*DC 34,9 & DCY 34,9 Amp
Draw 12V 65 110 180 370
24V 30 50 90 140
* These specifications are based on recommended 10 mm (.393”) 1960 grade wire rope.
6
180
5
4
3
2
1
0
270 360
MINUTES
AMPS
90 120 160 190
1
2
3
4
5
0
MINUTES
AMPS
Duty Cycles are shown below:
DUTY CYCLE
12V 24V
SPECIFICATIONS AND DUTY CYCLES

5
WARNINGS:
THE USER SHALL ENSURE THAT THE OPERATING PERSONNEL ARE GIVEN THE NECESSARY TRAINING.
THE OPERATOR SHALL ALWAYS WORK IN COMPLIANCE WITH THE OPERATING INSTRUCTIONS.
CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCH.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS.
STAND CLEAR OF ROPE WHILE PULLING. DO NOT TRY TO GUIDE ROPE.
DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PERSONNEL.
A MINIMUM OF 2 WRAPS OF ROPE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.
AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR. EXCESSIVE “INCHING” SHALL BE
AVOIDED.
User’s Responsibility for CE Compliance
1. Mount winch per Installation Instructions.
2. Install the emergency stop switch per Installation Instructions included with the Emergency Stop Switch Kit.
3. Install 10 mm (.393 in) grade 1960 wire rope. Maximum Rope length of 28 M (95 ft) for three layers maximum.
4. Attach rope to the drum per Rope Installation Instructions.
5. Use a hook which includes a safety latch and has a minimum breaking strength of 87 kN.
WARNINGS AND USER RESPONSIBILITY

6
WINCH MOUNTING
It is most important that this winch be mounted securely so that the three major sections (the clutch housing end, the rope
drum and the gear housing end) are properly aligned.
All standard model DC 34,9 winches are furnished with recommended mounting angles. Angle size is 9 x 63 x 63 x 914 mm
(3/8 x 2-1/2 x 2-1/2 x 36”) Lg. high strength 344,500 KPa (50,000 PSI) yield steel angle.
ROPE INSTALLATION
1. Unwind rope by rolling it out along the ground to prevent kinking. Securely wrap end of rope, opposite hook, with plastic or similar tape to pre
vent fraying.
2. Slide the wire rope through narrow end of the pocket against the drum flange. Wrap the wire rope around on the anchor “puck” (item
#38) and pull the wire rope and anchor back into the wide end of the pocket. Use a soft hammer to drive the back side of the wire rope,
firmly seating the wire rope and anchor into the pocket.
3. Carefully run winch in the “reel-in” direction. Keeping tension on end of rope, spool all the rope onto the rope drum, taking care to form
neatly wrapped layers.
TECHNIQUES OF OPERATION
The uneven spooling of rope, while pulling a load, is not a problem, unless there is a rope 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 rope
When pulling a load where there is even a remote chance of rope failure, place a blanket, jacket or tarpaulin over the rope about six feet
behind the hook. This will slow the snap back of a broken rope 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 0.35 L (0.75 pint) of all pur-
pose E.P. 140 oil in the worm gear housing and 0.23 L (0.5 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 ampere alternator. An auxiliary battery is rec-
ommended to supply additional battery power.
Inspect the rope frequently. If the rope becomes frayed with broken strands, replace immediately. The RAM-LOK®semi-automatic clutch
allows rapid unspooling of the rope, from rope 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 rope. Pull outward on the clutch han-
dle, rotate it counter-clockwise 90º and release. The clutch is now locked out and the rope may be pulled off by hand.
2. TO ENGAGE CLUTCH, pull outward on the handle, rotate it clockwise 90º and release. Run the winch in reverse until the clutch handle
snaps fully in or until the rope 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 rope.
CLUTCH
END
UNDERWOUND
MOTOR
END
ROTATION
DIRECTION
TO REEL IN
OVERWOUND
38
WINCH MOUNTING

7
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 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.
3. Lubricate rope with light oil.
B. MONTHLY
1. Lubricate the various grease fittings located in the rope drum, end bearing, clutch housing or clutch operating linkage. Any
good grade of moly-disulfide containing grease is acceptable.
2. Check the action of the sliding clutch, making sure it is fully engaging and disengaging with the rope 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 assem-
bly parts, check for damage or excessive wear and replace as necessary. Observe the jaws on both the clutch and rope 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. Inspect the rope. If the rope 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. Refill 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 inspec-
tion.
ELECTRICAL CONNECTIONS
For normal self-recovery work, your existing electrical system is adequate. Your battery must be kept in good condition. A
fully charged battery and proper connections are essential. Run the vehicle engine during winching operation to keep bat-
tery charged. Connect red cable from stud on plastic solenoid cover on winch to emergency stop solenoid. Important:
Hold inner nut with end wrench while tightening outer nut. Install emergency stop switch and solenoid per kit # 282067
(12V) or 282068 (24V) as applicable.
WINCH MAINTENANCE

8
ADJUSTMENT OF RATED LOAD LIMITER
1. Make some test pulls with winch (using a load cell or spring scale) to determine if switch is at desired rated load
setting.
Applicable setting is 100% to 125% of rated load.
2. If load is not within above range, remove tamper-proof compound in threaded hole (on top of set screws #4).
Remove top set screw.
3. Loosen bottom set screw approximately 2 turns counter clockwise.
4. To reduce line pull, thread switch #1 “IN” by turning clockwise. To increase line pull, the switch “OUT”.
5. After desired setting is reached, tighten bottom set screw securely.
6. Re-install top set screw and tighten securely. Fill threaded hole with a potting-type compound which must be
removed before any future adjustment is made.
End of Service Measures
When winch reaches the end of its serviceable life, dispose of per local environmental regulations.
NEGATIVE BATTERY POST
GROUND CABLE
ISOLATED GROUND
TERMINAL
SEE ILLUSTRATION
BELOW
ELECTRICAL CONNECTIONS (continued)
Connect black cable from motor ground stud to negative battery terminal. A good electrical ground is required for
proper performance. In applications where the chassis is non-grounded, a jumper wire (#440315) will be required
between the winch and the motor isolated ground terminal. (See Illustration Below)
The remote control switch is waterproof and has push button stations on either side. It is designed this way to
prevent quick winch reversals, which lead to solenoid failure. Make sure the winch motor has stopped fully before
reversing. When first setting up your winch, follow the directions for inserting the proper “IN” or “OUT” label in the
thumb button. The switch is also color coded to aid you in determining the direction your winch will run.
WINCH WILL NOT OPERATE UNLESS
GROUND CABLE IS INSTALLED FROM THE
ISOLATED GROUND TERMINAL TO THE
NEGATIVE BATTERY POST.
(SEE DIAGRAM BELOW)
JUMPER CABLE (#440315) MUST BE
INSTALLED ON WINCH FROM MOTOR
ISOLATED GROUND STUD TO GEAR
HOUSING COVER BOLTAS SHOWN
FOR NON GROUNDED CHASSIS
APPLICATIONS.
Isolated Motor Ground
For non-grounded chassis applications a jumper wire (#440315)
is required to ground the solenoid assembly
Non-Grounded Chasis Applications

9
CONDITION POSSIBLE CAUSE CORRECTION
CLUTCH INOPERATIVE OR
BINDS UP.
1. Dry or rusted shaft. 1. Clean and lubricate.
2. Bent yoke or linkage. 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.
3. Damaged gasket. 3. Replace gasket.
WINCH WILL NOT PULL RATED
LOAD 1. Rated load limiter mis-adjusted. 1. Adjust rated load limiter per instructions on page 5.
CABLE DRUM WILL NOT
FREE SPOOL.
1. Winch not mounted squarely, caus-
ing end bearings to bind drum.
1. Check mounting. Refer to WINCH MOUNTING Page 5.
CABLE BIRDNESTS WHEN
CLUTCH IS DISENGAGED.
1. Drag brake disc worn. 1. Replace discs.
MOTOR RUNS IN ONE
DIRECTION ONLY.
1. Inoperative solenoid or stuck sole-
noid.
1. Jar solenoid to free contacts. Check by applying 12 volts to coil
terminal (it should make an audible click when energized).
2. Inoperative switch. 2. Disengage winch clutch or remove armature lead. Remove switch
plug from hood. Raise connector cover on hood and with a
screwdriver, 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. 1-4. If clutch engaged but symptom still exists, it will be necessary
to disassemble winch to determine cause and repair.
2. Sheared drum shaft key.
3. Stripped bronze gear.
4. Parted shaft.
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.
1. Insufficient battery. 1. Check battery terminal voltage under load. If 10 volts or less,
replace or parallel another battery to it at motor terminal.
2. Electrical cables from battery to
winch too small.
2. Must be #2 gauge wire for distances up to 4,5 m (15 ft) from
battery to winch. Use larger than #2 gauge for distances greater
than 4,5 m (15 ft).
3. Bad electrical connections. 3. Check all connections for looseness or corrosion. Tighten, clean
and grease.
4. Insufficient charging system. 4. Replace with larger capacity charging system.
TROUBLESHOOTING GUIDE

10
CONDITION POSSIBLE CAUSE CORRECTION
MOTOR WILL NOT
OPERATE.
1. Inoperative solenoid or stuck sole-
noid.
1. Jar solenoid to free contacts. Check by applying 12 volts to coil
terminal (it should make an audible click when energized).
2. Inoperative switch. 2. Disengage winch clutch or remove armature lead. Remove switch
plug from hood. Raise connector cover on hood and with a
screwdriver, 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. Inoperative motor. 3. If solenoids operate, check for voltage at armature post, replace
motor.
4. Loose connections. 4. Tighten connections on bottom side of hood and on motor.

11
1. Drain oil from worm gear housing by removing (item #54)
plug from bottom of gear housing. Remove relief fitting
and reducer (items #51 & #53) from top of gear housing.
Remove mounting angles (items #9 & #80) from winch
by removing hardware shown
2. Drain oil from spur gear housing by removing (item #54)
plug. Remove cover and gasket (items #10 & #44) from
spur gear housing by unscrewing twelve capscrews (item
#30). Slide gear (item #14) from end of worm shaft (item
#25). Remove spur gear shaft (item #22), with gears
attached. Check bearings (item #28) 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 #5) by unscrewing capscrews
(items #32 & #35). Disconnect solenoid cables from
motor (item #3). Make note of which terminals cables are
attached to.
3. Remove key (item #47) and snap ring (item #65) from
worm shaft. Remove motor (item #3) from spur gear
housing (item #18) by removing (3) nuts and lock washers
(items #39 & #41). Unscrew (4) capscrews (item #34)
to remove spur gear box (item #18) 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.
INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL DC 34,9 SERIES RAM-LOK®
DIS-ASSEMBLY AND RE-ASSEMBLY

12
4. Slide clutch housing (item #19) from end of drum shaft. Slide jaw clutch (item
#9) from end of drum shaft.
Remove (2) keys (item #48) from keyways. A screwdriver can be used, at
notch, to aid in removal of keys. Once keys have been removed, drum (item
#12) and thrust washer (item #70) can be removed from drum shaft. Parts
under drum, thrust washer (item #69), spring and disc (item #66 & #42)
should also be removed.
5. Remove bearing cap (item #73) from gear housing by
unscrewing four capscrews (item #74). Remove worm
(item #25) and bearing (item #26) from gear housing.
Use a soft hammer to gently tap input end of worm and
drive worm and bearing from gear housing. Once worm
has been removed from housing, bearing can be pressed
from end of worm.
Check for signs of wear to worm (item #25) and bearings
(item #26). Replace if necessary.
For models with optional worm brake refer to page 6,
SERVICING OF THE OIL COOLED SAFETY BRAKE, for dis-
assembly and Page 7, for re-assembly instructions.
6. Remove gear housing cover (item #11) from gear housing
(item #20) by unscrewing five remaining capscrews (item
#31). 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
#23), with gear attached, and thrust washer (item #70)
from gear housing.
7. Check for signs of wear on gear teeth. If replacement of
gear is necessary, gear must be replaced as follows:
a. Press gear (item #16) from shaft (item #23).
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 #49) into key-
ways. Press gear (item #16) over shaft and keys. Gear must
be centered over keys.

13
8. Remove seal (item #63) from back of gear housing (item #20). Check bush-
ing (item #29) for signs of wear. Press bushing (item #29) from gear housing
and replace if necessary. Press new bushing and seal back into place.
9. Check drum bushings (item #27) for signs of wear. Replace if necessary by press-
ing old bushings from drum (item #12) and pressing new ones into place.
10. Examine shifter assembly (item #4) for damage to yoke. Yoke
should be firmly attached to shaft, yet, able to swivel freely
around shaft. Replace if necessary by removing pin (item #58)
from handle (item #17). Remove rubber plug (item #59) from
housing. Unscrew setscrew enough to allow shifter assembly to
be removed from housing.
Check clutch housing bushing (item #27) for signs of wear.
Remove if necessary by pressing old bushing from housing
(item #19) and pressing new one into place.
Install new shifter assembly (item #4) by placing end of shaft,
opposite yoke, through spring (item #67) and into housing
(item #19). Attach handle (item #17) to shaft using roll pin
(item #58). Tighten setscrew, in housing, enough to allow
shifter assembly to operate properly. Replace rubber plug.
11. Check cover bushing (item #11) for signs of wear. Replace if necessary
by removing old bushing and pressing new bushing into place.
12. Check pinion gear on motor for signs of wear. If necessary replace motor
(item #3).

14
13. Check gears of spur gear shaft assembly for signs of wear, replace if necessary.
Press old gears from shaft (item #22). Tap key (item #21) into keyway of shaft
(item #22). 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 bush-
ing in gear housing (item #20). Place greased end of shaft through
thrust washer (item #70) and bushing in gear housing (item #20).
Place gasket (item #45) onto gear housing cover (item #11).
Apply grease to gear end of shaft and bushing in cover. Place cover
onto shaft and secure to housing with five capscrews (item #31) at
the five lower most holes.
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 down-
wards 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 #12).
Slide drum assembly onto drum shaft with drum jaws
upward.
16. Place thrust washer (item #70) over end of drum shaft and slide downward until
spacer rests on drum. Press drum (item #12) downward to compress springs in
gear housing.
Insert keys (item #48) into keyways with sharp edge of keys pointing outward and
notched end of keys upward. 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 #9) over end of
shaft and slide jaw clutch over keys.
Set clutch housing (item #19) over end of drum shaft. Pull jaw clutch (item #9)
upward, toward clutch housing, enough to allow yoke, in clutch housing, to fit
properly in groove around jaw clutch.

15
17. Press bearing (item #26) onto worm (item #25). NOTE: Be sure thick shoulder
of bearings outer race (side with manufacturer’s name and part number) is out,
away from worm threads. Press bearing and worm into gear housing. Slip gas-
ket (item #43) onto bearing cap (item #73). Use four capscrews (item #74) to
secure cap to gear housing. Torque capscrews to 7 ft-lbs. (9.4 Nm) each.
Attach solenoid assembly (item #5) to gear housing. Use two (item #35)
capscrews and three (item #32) capscrews with three flatwashers (item #40).
Tighten capscrews to 7 ft-lbs. (9.4Nm) 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 #26) onto worm and into worm gear housing. NOTE: Be sure
thick shoulder of bearings outer race (side with manufacturer’s name and number)
is out, away from worm threads. Place gasket (item #43) onto spur gear housing
(item #18). Secure spur gear housing to worm gear housing using four capscrews
(item #34). Torque capscrews to 7 ft-lbs. (9.4 Nm) each.
Mount motor (item #3) to spur gear housing (item #18) using three lockwashers
and nuts (items #39 & #41). Attach solenoid cables to motor terminals. Tighten all
nuts securely.
19. Place snap ring (item #65) over end of worm shaft (item #25) and set into
snap ring groove. Insert key (item #47) into keyway of worm shaft. Place
thrust washer (item #68) over each end of spur gear shaft (item #22). Set
spur gear shaft assembly into bearing of spur gear housing. Slide gear (item
#14) and (item #68) thrust washer over end of worm shaft (item #25).
Insert pins (item #57) into cover (item #10). Place gasket (item #25)
onto cover. Attach cover and gasket to spur gear housing using twelve cap-
screws (item #30). Torque capscrews to 8 ft-lbs. (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 fitting (items #51 & #53) from top of spur gear hous-
ing. Pour .24 liters (1/2 pt) of SAE 20 weight motor oil into spur gear box.
Replace reducer and fitting into top of spur gear housing. Tighten reducer
and fitting securely.
20. Attach mounting angles (items #79 & #80) using six capscrews
(items #81) with lockwashers and capscrews (items #82 & #33).
Torque capscrews to 34 ft-lbs. (46 Nm.) each. Insert plug (item
#54) into bottom of gear housing. Permatex may be applied to
threads to help prevent leakage.
Pour .35 liters (3/4 pt) of E.P. 140 gear oil into housing thru hole
in top of housing. Insert relief fitting (item #51) into reducer (item
#53). Reducer should then be placed into hole on top of gear
housing. Tighten fitting and reducer securely.

16
CONNECT POWER CABLE FROM
EMERGENCY STOP SOLENOID HERE
SEE 282067 (12V) OR 282068 (24V)
.49
12,6
(TYP)
2.50
63,5
(TYP)
36.00 914,4
4.56
3.62
115,8
260,3
10.25
6.75
171,4
92,0
63,5 2.50
DRUM
1.37
DIS-ENGAGED
POSITION
CLUTCH AT
2.19 55,6
53,9 2.12
.69
63,5
2.50
17,5
34,9
89,9
Ø3.59
635,6 25.03
3.72
94,5
7.05
179,1 2.74
69,6
2.89
73,5
2.78
70,7
188,9
7.44
10.77
273,6
6.22
158,0
63,5
2.50
(TYP)
.25
6,4 (TYP)
CONNECT GROUND CABLE FROM
NEGATIVE (-) BATTERY TERMINALTO
MOTOR GROUND STUD
DC
A
B
290,5 11.44
227,0
8.94
160,3
6.31
287,3 11.31
134,1
5.28
197,6
7.78
C
INCHES
MM
B
INCHES
MM
A
MM
INCHES
DCY 34,9 DC 34,9
MODEL
WINCH MM
INCHES
D
13.12 333,3
8.12
206,3
DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS
DC 34,9 DIMENSIONAL DRAWING

17
SHOWN
NOT
2
82
81
41 79
80
1
7
6
69
42
66
66
42
48
48
37
27
83
78
84
74
76
72
73
78
85
77
23
70
9
27
19
58
17
50 59 60
67
4
38
27
12
39 41
43
49
49
26
51
53
63
47
65
26
43
62
18
34
28
57
10
30
55 57
44
68
14
13
28
68
54
21
14
22
68
28
64
53
51
54
25
20 29
70
16 27
45
11
31
56
61
35
40 32
5
8
3
86
33
81
81
81
81
41
41
41
75
TO BE INSTALLED HERE
SWITCH
WASHER
SETSCREW
BEARING CAP
WAVE WASHERS (ITEM #82)
SWITCH BUTTON
THRUST ACTUATOR
BEARING
THRUST DISC
RATED LOAD LIMITER
SECTION
GEAR HOUSING
DC 34,9 PARTS DRAWING

18
DC 34,9 PARTS LIST
Item No. Qty Part No. DescripƟon Item No. Qty Part No. DescripƟon
1 1 251110 SWITCH ASSEMBLY-12 FT.LG. 42 2 330010 DRAG BRAKE
282032 HEAVY DUTY SWITCH ASSY-12 FT. L
G
43 2 442184 GASKET
2 1 282067 E-STOP SWITCH KIT (12V) (NOT SH
O
44 1 442185 GASKET
1 282068 E-STOP SWITCH KIT (24V) (NOT SH
O
45 1 442205 GASKET
3 1 262039 MOTOR (12V) 46
1 262038 MOTOR (24V) 47 1 340023 KEY
4 1 276056 SHIFTER ASSEMBLY 48 2 450006 BARTH KEY
5 1 278028 SOLENOID ASSEMBLY (24V) 49 4 450016 BARTH KEY
1 278170 SOLENOID ASSEMBLY (12V) 50 1 456001 LUBE FITTING
6 1 289015 ASSEMBLY-WIRE, BATTERY CABLE,
R
51 2 456008 RELIEF FITTING
7 1 289141 ASSEMBLY-WIRE, GROUND, BLACK 52
8 1 434568 NAME AND DATA PLATE 53 2 468002 REDUCER
9 1 324160 JAW CLUTCH 54 2 468011 PIPE PLUG
10 1 328106 COVER-SPUR GEAR HOUSING 55 2 468017 PIPE PLUG
11 1 328134 COVER-GEAR HOUSING 56 1 468018 PIPE PLUG
12 1 332550 DRUM ASSEMBLY (STD) 57 2 470001 DOWEL PIN
1 332255 "Y" DRUM ASSEMBLY 58 1 470033 SPIRAL PIN
13 1 334001 IDLER GEAR 59 1 472012 PLUG
14 2 334003 SPUR GEAR 60 1 472013 PLUG
15 1 61 1 482013BOOT
16 1 334161 GEAR R.H.-60:1 62 1 486009 OIL SEAL
1 334163 GEAR R.H.-46:1 63 1 486017 OIL SEAL
17 1 336010 SHIFTER HANDLE 64 1 486023 OIL SEAL
18 1 338203 HOUSING-SPUR GEAR 65 1 490003 SNAP RING
19 1 338208 HOUSING-CLUTCH 66 2 494002 SPRING
20 1 338444 HOUSING-GEAR 67 1 494053 SPRING
21 1 342033 KEY 68 3 518002 THRUST WASHER
22 1 356901 SHAFT-SPUR 69 1 518014 THRUST WASHER
23 1 357479 SHAFT-DRUM (STD) 70 2 518015 THRUST WASHER
1 357481 SHAFT-DRUM ("Y") 71
25 1 368001 WORM-R.H. 60:1 72 1 282064 SWITCH ASSEMBLY
1 368019 WORM-R.H. 46:1 73 1 316093 BEARING CAP
26 2 402002 BALL BEARING 74 4 414857 SCREW-1/4-20NCX1.5LG,HXSOCHD,
N
27 4 412003 BUSHING 75 2 416003 SETSCREW-#10-24NCX3/8,HDLESOC,
C
28 3 402001 BUSHING 76 1 462039 O-RING
29 1 412045 BUSHING 77 1 518034 THRUST ACTUATOR
30 12 414038 CAPSCREW-1/4-20NCX3/4,HXHD,G 78 2 518087 THRUST DISC
31 5 414045 CAPSCREW-1/4-20NCX7/8 LG. HEX 79 1 302808 ANGLE (STD)
32 3 414059 CAPSCREW-1/4-20NCX1LG GR-5 HXHD Z/P 1 302811 ANGLE (Y)
33 1 414279 CAPSCREW-3/8-16NCX3/4 LG,HXH
D
80 1 302809 ANGLE (STD)
34 4 414845 CAPSCREW-1/4-20NC X1,HXSOCHD,NYLOK 1 302810 ANGLE (Y)
35 2 414856 CAPSCREW-1/4-20NCX3/4LG,HXS
O
81 6 414282 CAPSCREW-3/8-16NCX1 1/4LG,HXH
D
36 82 1 414912 CAPSCREW-3/8-16NC X5/8LG,HXSO
C
37 1 416030 SETSCREW-1/4-20NCX3/8,HXSOC,F 83 1 416285 SETSCREW-#10-24NCX3/8,HDLESOC,
C
38 1 315008 ROPE ANCHOR 84 1 418223 WASHER-1/2 USS FLAT,ZINC PLATED
39 3 418040 NUT-3/8-24NF HEX REG ZINC PLAT
E
85 1 418204 WASHER-7/16 USS FLAT,ZINC PLATE
D
40 3 418154 WASHER-1/4 FLAT ALUM. 86 11 494119 WASHER-WAVE
41 10 418177 LOCKWASHER-3/8 MED SECT,ZINC

19
7
10
3
20 20
16
17
7
4
11
20
4
2
16
25
17
6
5
20
9
2
1
14
10
12
10 13
19
918
15
8
8
Yellow
Red
Green
Additional Hardware comes
supplied with Solenoid.
A
B
C
278027 - 12V
278028 - 24V
Item
No Qty Part No. DescripƟon
1 1 280009 Cable-Bolt Assembly
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- 3/16-18 NC Hex Reg
11 2 418140 Flat Washer #10
12 2 418141 Lockwasher #10
13 1 418163 Lockwasher 5/16 Med Sect Zinc
14 1 418164 Shake Proof Washer 5/16 Internal
15 1 418165 Shake Proof Washer 5/16 External
16 1 430013 Female Connector
17 2 440071 Terminal-Tab
18 2 440110 Solenoid – 12 V
2 440114 Solenoid – 24 V
19 1 472071 Solenoid Cover
20 1 482029 Cover-Connector
Solenoid Assembly Parts

20
TEST PROCEDURE FOR SOLENOIDS
Steps to follow when testing current flow through DC sole-
noids.
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 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 isolated ground terminal.
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 17).
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; i.e. connected, and
the side terminals open, or not connected. When the sole-
noid 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.
TEST PROCEDURE FOR SOLENOIDS
A
F1
F2
ISOLATED GROUND
TERMINAL
BATTERY
FIGURE-1
GROUND WIRE(-) FROM
SOLENOID TO MOTOR
MOTOR
SOLENOID
(TOP TERMINALS)
SIDE SIDE
(SMALL) (SMALL)
SIDESIDE
(TOP TERMINALS)
SOLENOID
MOTOR
GROUND WIRE(-) FROM
SOLENOID TO MOTOR
FIGURE-2
BATTERY
ISOLATED GROUND
TERMINAL
F2
F1
A