OPERATING,SERVICE, AND MAINTENANCE MANUAL MODELS DC•7/DC•7B SERIES INDUSTRIAL LOW-MOUNT WINCHES CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH.
TABLE OF CONTENTS INTRODUCTION ....................................................... 1 WARRANTY INFORMATION ....................................................... 1 SPECIFICATION ....................................................... 1 TECHNIQUES OF OPERATION ....................................................... 2 WARNINGS ....................................................... 2 WINCH MAINTENANCE ....................................................... 3 WINCH MOUNTING ............
RAMSEY ELECTRICAL WINCH MODEL DC-7 SERIES PLEASE READ THIS MANUAL CAREFULLY This manual contains useful ideas in obtaining the most efficient operation from your Ramsey Winch, and safety procedures one needs to know before operating a Ramsey Winch. WARRANTY INFORMATION Ramsey Winches are designed and built to exacting specifications. Great care and skill go into every winch we make. If the need should arise, warranty procedure is outlined on the back of your self-addressed postage paid warranty card.
TECHNIQUES OF OPERATION The best way to get acquainted with how your winch operates is to make test runs before you actually use it. Plan your test in advance. Remember, you hear your winch, as well as see it operate. Get to recognize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Gain confidence in operating your winch and its use will become second nature with you.
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 cable with light oil. B. MONTHLY 1.
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-7/DC-78 Series Winches are furnished with recommended mounting angles. Model DC-7 Winch is furnished with 1/4 x 2 x 2 high strength steel angles. Model DC78 Winch is furnished with 3/16 x 1-1/2 x 2 high strength steel angle.
TROUBLE SHOOTING GUIDE CONDITION POSSIBLE CAUSE CORRECTION 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. 1. Inoperative solenoid or stuck solenoid. 1. Jar solenoid to free contacts. Check by applying volts to coil terminal (it should make an audible click when energized). (See Page 19) MOTOR RUNS IN ONE DIRECTION ONLY. 2. Remove switch plug from hood.
INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL DC-7/DC-7B SERIES WINCHES DISASSEMBLY 1. Drain oil from worm gear housing by removing (item #51) plug from bottom of gear housing. Remove relief fitting and reducer (items #46 & #54) from top of gear housing. Remove winch from mounting angles (items #6 & #7) by removing hardware shown (items #34 & #40). NOTE: DC-7B WINCH SHOWN. See Pg. 14 & 15 for mounting brackets and hardware for DC-7 winch. 2.
4. Slide end bearing (item #17) and drum (item #11) from drum shaft. Remove two keys (item #22) from drum shaft. 5. Remove bearing cap (item #8) and gasket (item #42) from gear housing by unscrewing four capscrews (item #33). Remove worm (item #26) and bearing (item #28) 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.
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 #15) from shaft (item #23). b) Examine shaft keys (item #22) and keyways. If distortion of keys and/or keyways is evident, shaft and keys should be replaced. c) Tap keys (item #22) firmly into shaft keyways. Press shaft and keys through gear keyways until end of keys, on long end of shaft are flush with gear. 8. Remove seal (item #58) from back of gear housing (item#19).
.Check cover bushing (item #30)for signs of wear. Replace if necessary by removing old bushing and pressing new bushing into place. 12. Check motor for signs of wear. If necessary replace motor (item #47) 13. Check gears (items #13 & #14) of spur gear shaft assembly for signs of wear, replace if necessary. Press old gears from shaft (item #25). Tap key (item #21) into keyway of shaft (item #25). Press shaft through gears so that gears are centered on shaft and key. 14.
15. Place winch, with gear housing cover down, onto work bench. Drum shaft should be in vertical position. Place keys (item #22) into keyways of shaft. A rubber or brass mallet will be needed to gently tap keys into position. Apply grease to keys and end of shaft. Slide keyway end of drum (item #11) over drum shaft and keys. Apply grease to bushing in end bearing (item #17) and end of drum shaft. Slide end bearing over end of drum shaft. 16. Press bearing (item #28) onto worm (item #26).
18. Place snap ring (item #60) over end of worm shaft (item #26) and set into snap ring groove. Insert key (item #20) into keyway of worm shaft. Place thrust washer (item #61) over each end of spur gear shaft (item #25). Set spur gear shaft assembly into bearing of spur gear housing. Slide gear (item #14) and thrust washer over end of worm shaft. Insert pins (item #55) into spur gear housing (item #18). Attach cover (item #10) and gasket (item #43) to spur gear housing using twelve capscrews (item #32).
DIMENSIONAL DRAWING DC7 / DCX7 12
DIMENSIONAL DRAWING DC-7B / DCX-7B 13
PARTS LIST MODEL DC-7 & DC-7X 12V & 24V PART NO. QTY. QTY. DESCRIPTION ITEM NO. QTY. PART NO.
MODEL DC-7 AND DCX-7 12 V & 24 V EXPLODED VIEW 15
PARTS LIST MODEL DC-7B & DC-7BX 12V & 24V PART NO. QTY. QTY. DESCRIPTION ITEM NO. QTY. PART NO.
MODEL DC-7B AND DCX-7B 12 V & 24 V EXPLODED VIEW 17
SOLENOID ASSEMBLY PARTS 278035 - 12 V 278036 - 24 V ITEM NO. QTY. PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 18 1 1 1 1 2 2 1 2 4 2 2 2 2 1 1 1 1 1 1 2 1 280009 289077 289091 328104 364001 364002 408038 416199 416216 418004 418022 418140 418142 418163 418164 418165 430013 440114 440110 440071 482029 DESCRIPTION CABLE&BOLT ASSY-W/ALL 12&24V SOLE WIRE ASSY-4.
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. 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.
TEST PROCEDURE FOR MOTOR The Ramsey Winch motor is a (4 pole-4 coil) series 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 properly, first securely fasten the motor to a bench or work surface so it will not jump or move around during test procedure (the starting torque of motor is high). 1. Connect a jumper wire (at least a number 6 wire) from F-1 to “A” motor terminals (See Figure 1). 2.
NOTES 21
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.
