Subscribe to Our Youtube Channel
Related Manuals for Ramsey Electronics DCY200
Summary of Contents for Ramsey Electronics DCY200
- Page 1 RAMSEY ELECTRIC WINCH MODEL DCY/DC200 PART NO - 3561 / 3560 FITTING & OPERATING INSTRUCTIONS...
-
Page 2: Table Of Contents
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 .................... -
Page 3: Guide To Safe Winching
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. -
Page 4: Warning
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. -
Page 5: Fitting Instructions
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. -
Page 6: Above Deck Mounting
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. -
Page 7: Front Mounting
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. -
Page 8: Wanderlead Remote Socket
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. - Page 9 available for both single and double rear sockets. Part numbers SC0125 and SC0150. (See wiring diagram below).
-
Page 10: Emergency Stop
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. -
Page 11: Testing
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. -
Page 12: Free Spooling
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. -
Page 13: Oil Spec
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. -
Page 15: Trouble Shooting Tips
TROUBLE SHOOTING TIPS CONDITION POSSIBLE CAUSE CORRECTION CLUTCH INOPERATIVE 1) Dry or rusted shaft. 1) Clean and lubricate. OR BINDS UP. 2) Bent yoke or linkage. 2) Replace yoke or shaft assembly. 3) Clutch jaws are in 3) See techniques of contact. - Page 16 TROUBLE SHOOTING (cont'd.) CONDITION POSSIBLE CAUSE CORRECTION MOTOR RUNS 1) Long period of operation. 1) Cooling-off periods are EXTREMELY HOT essential to prevent over heating. MOTOR RUNS, BUT 2) Insufficient battery. 2) Check battery terminal voltage WITH under load. If 10 volts or less, INSUFFICIENT POWER replace or parallel another OR WITH...
- Page 17 TROUBLE SHOOTING (cont'd.) CONDITION POSSIBLE CAUSE CORRECTION MOTOR WILL NOT 6) Inoperative motor. 6) If solenoids operate, check OPERATE for voltage at armature post, replace motor. 7) Loose connections. 7) Tighten connections on bottom side of hood and on motor.
-
Page 18: Winch Parts List
WINCH PARTS LIST Item Qty. Part Description Item Qty. Part Description Req'd Req'd 276028 Shifter Assembly* 342023 Key-Square 278027 Solenoid Assembly-12V 342033 Key-Square 278028 Solenoid Assemb!y-24V 356901 Shaft-Spur 282001 Switch Assembly 357479 Shaft-Drum-Std 302808 Angle (std) 357481 Shaft-Drum-Mod Y 302811 Angle (mod Y) 368001 Worm-R.H. -
Page 19: Solenoid Assembly Parts
Item Qty. Part Description Item Qty. Part Description Req'd Req'd 418177 Lockwasher 3/8 Med Sect 494053 Spring 438014 Drag Brake 518002 Thrust Washer 442184 Gasket 518014 Thrust Washer 442185 Gasket 518015 Thrust Washer 442205 Gasket 518018 Fibre Washer 450001 Key 450006 Key –... -
Page 20: Test Procedure For Solenoids
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. -
Page 21: Test Procedure For Motor
TEST PROCEDURE FOR MOTOR The Ramsey Winch motor is a 4 pole, 4 coil wound 12 volt or 24 volt DC motor. The 4 pole, 4-coil feature provides high torque at low speeds To test the motor to determine if it is functioning correctly, firstly securely fasten the motor to a bench or work surface so it will not jump or move around... -
Page 22: Instructions For Overhaul Of Ramsey
The motor running idle on the bench will draw 55 amperes and must run free and easy. If the ampere draw is more than 60 amps and the motor runs rough or has a strange sound, it should be replaced. With the motor attached in place on a winch (less cable on drum) the ampere should be approx. - Page 23 Remove solenoid assembly (item 2) by unscrewing capscrews (items 30 & 34). Disconnect solenoid cables from motor (item 51). Make note of which terminals cables are attached to. 3. Remove key (item 19) and snap ring (item 65) from worm shaft. Remove motor (item 51) from spur gear housing (item 16) by removing (3) nuts and lockwashers (items 39 &...
- Page 24 6. Remove gear housing cover (item 8) from gear housing (item 18) by unscrewing five remaining capscrews (item 28). Place capscrews 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 22), with gear attached, and thrust washer (item 70) from gear housing.
- Page 25 9. Check drum bushings (item 26) for signs of wear. Replace if necessary by pressing old bushings from drum (item 10) and pressing new ones into place. 10. Examine shifter assembly (item 1) for damage to yoke. Yoke should be firmly attached to shaft, yet, able to swivel freely around...
-
Page 26: Re-Assembly
tube to drive pinion down hard enough to seat O-ring (item 52) into groove in bottom of pinion gear. C. Slide pinion gear up toward end of shaft so that there is a 1-13/16” distance from top of gear to cast surface below gear. - Page 27 16. Place thrust washer (item 70) over end of drum shaft and slide downward until spacer rests on drum. Press drum (item 10) downward to compress springs in gear housing. Insert keys (item 47) into keyways with sharp edge of keys pointing outward and notched end of keys upward.
- Page 28 18. Press bearing (item 24) 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 16). Secure spur gear housing to worm gear housing using four capscrews (item 33).
-
Page 29: Warranty
20. Attach mounting angles (items 4 & 5) using six capscrews (item 32) with lockwashers and capscrews (items 35 & 31). Torque capscrews to 34 ft. lb. (46Nm). each. Insert plug (item 54). Into bottom of gear housing. Permatex may be applied to threads to help prevent leakage. -
Page 30: Appendix
APPENDIX BATTERIES As a result of radical changes in vehicle battery design and performance that have taken place over the last 18 months it is essential that the correct type are specified on new vehicles that will include an electric winch or other high electrical power consumer. Heavy Duty ED3/VB3 rated should be specified as these are vibration proof and have 2.5mm thick plates compared to the standard 1.5mm.
Need help?
Do you have a question about the DCY200 and is the answer not in the manual?
Questions and answers