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Page 1: ...RAMSEY ELECTRIC WINCH MODEL DCY DC200 FITTING OPERATING INSTRUCTIONS Manual Part No 10928 19 12 18 PART NO 3561 3560...
Page 2: ...0 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 AR...
Page 3: ...ull 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 o...
Page 4: ...n 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...
Page 5: ...tive 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 T...
Page 6: ...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...
Page 7: ...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 VOLTAG...
Page 8: ...OMMENDED 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...
Page 9: ...available for both single and double rear sockets Part numbers SC0125 and SC0150 See wiring diagram below 9...
Page 10: ...en 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...
Page 11: ...utton 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 recog...
Page 12: ...NCE 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 chec...
Page 13: ...ble 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 use...
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Page 15: ...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...
Page 16: ...on 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...
Page 17: ...ITION 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 s...
Page 18: ...ear 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...
Page 19: ...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 S...
Page 20: ...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 sh...
Page 21: ...ber 25mmsq 170 amp wire from positive battery terminal to F 2 motor the motor and battery terminal Ground negative battery terminal to motor housing See fig 2 Motor should now run To reverse the direc...
Page 22: ...onnection to INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL DC 200 SERIES RAM LOK DIS ASSEMBLY 1 Drain oil from worm gear housing by removing item 54 plug from bottom of gear housing Remove relief fitting...
Page 23: ...m 17 from end of drum shaft Slide jaw clutch item 7 from end of drum shaft Remove 2 keys item 47 from keyways A screw driver can be used at notch to aid in removal of keys Once keys have been removed...
Page 24: ...eth If replacement of gear is necessary gear must be replaced as follows 1 Press gear item 14 from shaft item 22 2 Examine shaft keys and keyways If distortion of keys and or keyways are evident shaft...
Page 25: ...essing new one into place Install new shifter assembly item 1 by placing end of shaft opposite yoke through spring item 67 and into housing item 17 Attach item 15 handle to shaft using roll pin item 5...
Page 26: ...ply grease to end of shaft opposite gear Apply grease to bushing in gear housing item 18 Place greased end of shaft through thrust washer item 71 and bushing in gear housing item 18 Place gasket item...
Page 27: ...using enough to allow yoke in clutch housing to fit properly in groove around jaw clutch 17 Press bearing item 24 onto worm item 23 NOTE Be sure thick shoulder of bearings outer race side with manufac...
Page 28: ...ring groove Insert key item 19 into keyway of worm shaft Place thrust washer item 68 over each end of spur gear shaft item 21 Set spur gear shaft assembly into bearing of spur gear housing Slide gear...
Page 29: ...nt is the owner s together with its return transportation prepaid to BHW Group Ltd BHW Group Ltd will under this Warranty without charge repair or replace at its option parts which on inspection are d...
Page 30: ...These batteries are designed to discharge around 15 of their total capacity and then recharge quickly from the alternator The duty cycle design criteria for vehicle batteries is to crank a cold engin...
