OPERATING, SERVICE AND MAINTENANCE MANUAL MODEL DCS-200 ELECTRIC INDUSTRIAL SPEED REDUCER EZ ANCHOR CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH.
TABLE OF CONTENTS INTRODUCTION ………………………………………… 1 WARRANTY INFORMATION ………………………………………… 1 SPECIFICATION ………………………………………… 1 WARNINGS ………………………………………… 1 MAINTENANCE ………………………………………… 2 TROUBLE SHOOTING GUIDE ………………………………………… 3-4 INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL DC-S200 SERIES ………………………………………… DISASSEMBLY & REASSEMBLY 5-9 DIMENSIONAL DRAWING ………………………………………… 10 PARTS LIST AND PART DRAWING ………………………………………… 11-12 SOLENOID ………………………………………… 13 LIMITED WARRANTY ………………………………………
RAMSEY ELECTRIC SPEED REDUCER MODEL DCS-200 SERIES PLEASE READ THIS MANUAL CAREFULLY This manual contains useful ideas in obtaining the most efficient operation from your Ramsey Speed Reducer, and safety procedures one needs to know before operation. WARRANTY INFORMATION Ramsey Speed Reducers are designed and built to exacting specifications. Great care and skill go into every speed reducer we make. If the need should arise, warranty procedure is outlined on the back of this manual.
WINCH MAINTENANCE Adhering to the following maintenance schedule will keep your speed reducer in top condition and performing as it should with a minimum of repair. A. WEEKLY 1. 2. B. MONTHLY 1. C. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and repair. 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. Check the speed reducer bolts.
WINCH MOUNTING WINCH MOUNTING It is most important that this winch be mounted securely so that the three major sections (the clutch housing end, the cable drum and the gear housing end) are properly aligned. All standard model DC-200 Series Winches are furnished with recommended mounting angles. Angle size is 1/4 x 2-1/2 x 2-1/2 x 36” Lg. high strength (50,000 PSI yield) steel angle. ELECTRICAL CONNECTIONS See dimensional drawing on page 18.
TROUBLE SHOOTING GUIDE CONDITION OIL LEAKS FROM HOUSING MOTOR RUNS IN ONE DIRECTION MOTOR RUNS, BUT OUTPUT SHAFT DOES NOT TURN. POSSIBLE CAUSE 1. Seal damaged or worn. 2. Too much oil 3. Damaged gasket 1. Inoperative solenoid or stuck solenoid. 2. Inoperative switch. 3. Broken wire or bad connection. 1. Sheared drum shaft key. 2. Stripped bronze gear. 3. Parted shaft. 6 CORRECTION 1. Replace seal. 2. Drain excess oil. Refer to TECHNIQUES OF OPERATION. 3. Replace gasket. 1.
CONDITION MOTOR RUNS EXTREMELY HOT. POSSIBLE CAUSE 1. Long period of operation. 2. Insufficient battery. MOTOR RUNS, BUT WITH INSUFFICIENT POWER, OR WITH LOW RPM. 3. Electrical cables from battery to speed reducer too small. 4. Bad electrical connections. 5. Insufficient charging system. 1. MOTOR WILL NOT OPERATE. CORRECTION 1. Cooling-off periods are essential to prevent over-heating. 2. Check battery terminal volt age under load.
INSTRUCTIONS FOR OVERHAUL OF RAMSEY DCS-200 SPEED REDUCER 1. Drain oil from worm gear housing by removing (item #35) plug from bottom of gear housing. Remove relief fitting and reducer (items #32 & #34) from top of gear housing. Remove Speed Reducer from mounting. 2. Drain oil spur gear housing by removing (item #35) plug. Remove cover and gasket (items #5 & #29) from spur gear housing by unscrewing twelve cap screws (item #20). Slide gear (item #7) from end of worm shaft (item#15) with gears attached.
4. Remove bearing cap (item #3) from gear housing by unscrewing four cap screws (item #21). Remove worm (item #15) and bearing (item #17) 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 #15) and bearings (item #17). Replace if necessary. 5.
7. Remove seal (item #41) from back of gear housing (item #10). Check bushing (item #19) for signs of wear. Press bushing (item #19) from gear housing and replace if necessary. Press new bushing and seal back into place. 8. Check cover bushing (item #18) for signs of wear. Replace if necessary by removing old bushing and pressing new bushing into place. 13 9. Check gears of spur gear shaft assembly for signs of wear, replace if necessary. Press old gears from shaft (item #13).
10. Press bearing (item #17) onto worm. (item #15). 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 gasket (item #28) onto bearing cap (item #3). Use four cap screws (item #21) to secure cap to gear housing. Torque cap screws to 7 ft-lbs (9.4 Nm) each. Attach solenoid assembly (item #1) to gear housing.
. Place snap ring (item #43) over end of worm shaft (item #15) and set into snap ring groove. Insert key (item #11) into key way of worm shaft. Place thrust washer (item #44) over each end of spur gear shaft (item #13). Set spur gear shaft assembly into bearing of spur gear housing. Slide gear (item #7) and (item #44) thrust washer (item #44) over end of worm shaft (item #15). Insert pins (item #38) into cover (item #5). Place gasket (item #29) onto cover.
NOTES 13
1.25 14 160420 160419 160418 160417 WINCH MODEL C A INCHES MM 8.50 215,9 11.00 279,4 12.50 317,5 16.44 417,6 B A 2.50 63,5 10.68 271,3 3.63 92,1 B INCHES MM 10.24 260,1 12.74 323,6 14.24 361,7 18.18 461,8 C INCHES MM 17.55 445,7 20.05 509,3 21.55 547,4 25.49 647,4 7.05 179,1 7.44 188.9 10.77 273,6 10.77 273,6 CONNECT GROUND CABLE FROM NEGATIVE BATTERY TERMINAL TO MOTOR GROUND STUD DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS 1.37 34,9 1.13 28,7 4.00 101,6 6.
20 5 36 38 29 38 16 44 16 6 44 7 16 23 7 12 13 9 32 35 34 31 44 14 25 27 40 28 17 41 42 31 34 33 35 47 19 10 32 45 43 11 8 46 15 17 2 28 18 30 3 21 4 21 37 22 1 39 SEE PAGE 18 FOR COMPONENT BREAKDOWN 24 26 MODEL DCS - 200 12V EXPLODED VIEW
21 22 9 3 420010 CAPSCREW-1/4-20NCX7/8 LG. HEX HD, SS 420011 CAPSCREW-1/4-20NCX1LG, HXHD, SS ITEM NO QTY. PART NO. DESCRIPTION 1 1 278027 SOLENOID ASSEMBLY - 12V 2 1 282001 SWTICH ASSEMBLY 3 1 316083 CAP BEARING 4 1 328134 COVER WORM GEAR HSG 5 1 328106 COVER SPUR GEAR HSG 6 1 334239 GEAR 7 2 334003 GEAR 8 1 334161 GEAR R. H. - 60:1 9 1 338203 HOUSING SPUR GEAR 10 1 338273 HOUSING GEAR 11 1 342023 KEY SQUARE 12 1 342033 KEY SQUARE 13 1 356901 SHAFT SPUR 14 1 357554 SHAFT 1 1/4 X 11.
SOLENOID ASSEMBLY PARTS ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 8 QTY. 1 3 1 2 2 1 2 2 2 2 2 1 1 1 1 2 2 1 1 4 PART NO 280009 289077 289091 364001 364002 408035 416283 416277 418536 418531 418140 418532 418533 418534 430013 440071 440110 472071 482029 530106 DESCRIPTION CABLE - BOLT ASS'Y WIRE ASS'Y WIRE ASS'Y STRAP STRAP SOLENOID BRACKET SCREW-#10-24UNC SS SCREW-#10-24UNC NUT-HEX #10-24NC REG., SS NUT-5/16-18NC HEX REG.
LIMITED WARRANTY RAMSEY WINCH warrants each new RAMSEY Winch to be free from defects in material and workmanship for a period of one (1) year from date of purchase. The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at the Manufacturer’s factory, or at a point designated by the Manufacturer, of such part that shall appear to the Manufacturer, upon inspection of such part, to have been defective in material or workmanship.
