FITTING & OPERATING INSTRUCTIONS

Transcription

1 FITTING & OPERATING INSTRUCTIONS RAMSEY DC ELECTRIC WINCH MODEL DC-34.9 Part Nos: 12v = v = 9932 CONFORMING TO EN Cranes Power driven winches and hoists Part 1: Power Driven Winches Part No /

2 CONTENTS INTRODUCTION 3 NEW EUROPEAN STANDARDS & BHW GROUP LIMITED 3 INSTALLER RESPONSIBILITY FOR CE COMPLIANCE 4 WINCH INFORMATION WINCH SPECIFICATIONS 5 WINCH PERFORMANCE 5 WINCH DIMENSIONS 6 WINCH LABELS 7 INSTALLATION WINCH MOUNTING 8-9 POWER SUPPLY FROM BATTERY 10 ISOLATOR SWITCHES AND HEAVY DUTY FUSES 11 LOAD LIMITING DEVICE WANDERLEAD REMOTE SOCKETS 15 EMERGENCY STOP 16 TESTING TESTING THE WINCH 16 TRIALLING THE WINCH 16 TEST PROCEDURES FOR MOTOR 17 TEST PROCEDURES FOR SOLENOID 18 WIRE ROPE WIRE ROPE INSTALLATION 19 OPERATING INSTRUCTIONS SAFETY PRECAUTIONS 20 RATING THE WINCH 21 OPERATING THE WINCH 21 FREESPOOLING (RAM LOCK CLUTCH) AND CAPACITIES 21 MAINTENANCE MONTHLY MAINTENANCE 22 ANNUAL MAINTENANCE 22 CARE OF THE WIRE ROPE 22 WINCH PARTS PARTS DIAGRAM 23 PARTS LIST 24 SOLENOID PARTS & LIST 25 TROUBLESHOOTING 26 OVERHAUL INSTRUCTIONS DIS-ASSEMBLY 27 RE-ASSEMBLY 30 NOTES ON BATTERIES 32 WARRANTY 33 2

3 INTRODUCTION PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLATION OR OPERATION OF THE WINCH Those responsible for the installation and the operation of this winch must read and understand this manual. The first section deals with the installation requirements and the second section is for the user and provides information to ensure safe use of the winch. Ramsey Winches are widely used for commercial purposes throughout the world. The winch is of the highest quality and has been designed to give a robust and efficient service for many years if care and attention are given at all times to correct installation, operation and maintenance. PLEASE KEEP THIS OWNERS MANUAL WITH THE WINCH EUROPEAN STANDARDS & BHW GROUP LIMITED The harmonised European standard: EN for power driven winches provide the means for conformity to essential Health and Safety requirements of the EN Machinery Directive. This standard is law throughout the European Union and must be applied. Conformity to these standards is the joint responsibility of the winch supplier, the installer and the company operating the machine. Selecting the correct winch for the application is very important not only from the health and safety aspect, but also to maximise product life and value for money by reducing maintenance costs and vehicle down time. BHW Group Limited products are fully compliant and carry a CE mark. A Declaration of Conformity is also supplied with each winch. BHW Group Limited aim to ensure the correct machine is supplied to suit the application and we welcome the opportunity of discussing the proposed application and offer advice. It will help us considerably if information regarding the maximum and average loads to be lifted or pulled - and approximate frequency of use can be provided. This winch is to be used only for the purpose of vehicle recovery when fitted to equipment designed for the purpose, or the loading of wheeled vehicles upon bodies designed for the purpose, or used for a purpose specifically agreed with the BHW Group Limited. For recovery vehicles the permissible standard of wire rope MBF** to winch rating must be a minimum 2:1 and the ratio of wire rope to mean drum diameter* only 10:1. This minimum standard is permitted because the running time for recovery winches is so short and the winch rarely sees maximum load. Whilst the requirements of this standard are very reduced compared to lifting winches it imposes a much higher standard of safety than those that before The new line pull ratings shown overleaf reflect this improved safety level. Winches with the potential to apply forces over 1000kg must be load limited to prevent them applying loads above the safe working capacity. Maximum wire rope length permissible on the drum must leave 1.5 x wire rope diameter from the top layer to drum flange. The standard EN considers all types of winches used for all applications and suggests guards are fitted if there is a chance an operator may become entangled. Personnel using vehicle-mounted winches are not generally close to the winch drum during recovery for this risk to occur. It is also important for the safety and ease of operation for the user to clearly see the wire rope wrapping onto the drum to ensure serious bunching and resulting jamming does not occur. Winches can be used in many different applications and the user or installer should carry out a risk assessment to determine any guarding that may be required. In an application where hand tension is applied to the hook whilst the rope is being wound back on to the drum for storage there is a risk of the hand being pulled into the roller guide or drum. A short webbing strap should be used that is looped onto the hook to prevent the risk of this occurring (See picture on front of manual). These straps are supplied with wire rope provided with new winches and are available as a replacement part (No.9867) from BHW Group, or online at * Mean drum diameter = the drum diameter plus the diameter of the wire rope. ** MBF = the Minimum Breaking Force of the wire rope. 3

4 INSTALLER RESPONSIBILITY FOR CE COMPLIANCE 1. Mount winch in accordance with instructions. IMPORTANT NOTE: The direction of drum rotation during winching must be observed to ensure correct functioning of the overload device and the winch brake as this is only active in one direction. 2. Install an emergency stop switch in accordance with installation instructions included in this manual. (See page19). There are also options listed of BHW Emergency Stop systems listed in this section. 3. Install 10 mm 1960N/mm² grade, 6/36wire core rope with minimum breaking strain of 68.9kN (7027kgf) Maximum rope length of 23m x 3 layers. This is the maximum rope length permissible to ensure compliance with EN as this requires a 1.5 x wire rope diameter from the top layer to the drum flange.. 4. Attach rope to the drum as per WIRE ROPE INSTALLATION INSTRUCTIONS. (Page 22). 5. Hook must have a safety latch and a minimum rated capacity of 2.0 Tonne. Use only high tensile grade 80 or 100. These hooks are rated and stamped for lifting and have a safety factor of 4:1. A 2.0 Tonne hook has therefore a minimum yield of 2 x 4 = 8 tonne. For pulling applications with a 2:1 factor of safety they are suitable for up to 4.0 tonne line pull. 6. Install a heavy duty, slow burn fuse in fuse carrier as close to the battery as possible to prevent fire risk. For 12v winches this should be rated at 300amp and for 24v use 200 amp. Details on heavy duty fuses can be found on page Load test the winch following installation to check the integrity of the mounting and adjust to ensure the correct load setting is achieved. See page 19. FITTING INSTRUCTIONS The Ramsey Winch has a worldwide reputation for toughness and reliability. The design of this long established product has been well proven over the years for many applications. Like all machines it must be installed correctly in accordance with these fitting instructions (Pages 8-15) and subsequently the user must also adopt the correct procedures as those included in the section headed operating instructions (Pages 23-24). Irrespective 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. WINCH ROTATION VERY IMPORTANT The DC-34.9 is fitted with a load limiting device and for this to function the winch must be positioned correctly so the drum rotation viewed from the freespool clutch end is anti-clockwise when pulling in. In addition the wire rope wedge anchor should only be fitted to allow anti-clockwise rotation when pulling in as viewed from the freespool clutch end. 4

5 WINCH INFORMATION WINCH SPECIFICATIONS Model Typical Uses Construction Motor Gear Type Ramsey DC Tonne DC Worm & Wheel Drive EN Compliant Plant and commercial recovery work Die cast aluminium end housings with steel drum High torque series wound 12v (1.9hp) 24v (2.5hp) High carbon steel worm and phosphor bronze wheel combined with motor driving through spur gear box Gear Reduction Braking Wanderlead Freespool Clutch Drum Rotation 470:1 for either 12v or 24v versions. Heavy duty self-locking worm and wheel holds load until winch is powered out. Tough, 2 button hand held control with 4.5m lead. Other lengths available on request. 3 button controls that include an emergency stop button are available if a solenoid safety shut down system has been provided (available as an option). Ram-Lok type with engagement in two location positions per drum revolution. Counter clockwise viewed from freespool clutch end when pulling in. Recommended Wire Rope 10mm dia.(max.)1960n/mm 2 grade 6 x 36 wire core construction with 68.9kN (7027kgf) minimum braking strain must be used to comply with EN standards. Recommended length is 30m maximum. Recommended Hook 2 tonne rated with safety latch. Use only high tensile grade 80 or 100 to comply with EN standards. Load Limiting Lubrication & Recommended Oils Weight Drum Dimensions Winch on its own supplied with mechanical overload protection. Winch supplied in standard mounting bracket (Part No. 3686) has optional mechanical overload or electronic type. Winch supplied in upright foot mounting bracket (Part No. 3688) supplied with electronic load limiter protection. Worm and wheel and spur gear run in oil baths. Worm & Wheel Gearbox: EP90 (0.58 litres). Spur Gearbox: EP20 (0.29 litres). Winch only = 53kg. Winch complete with mounting plate, roller guides and wire rope = 68kg. 90mm diameter x 287mm. Flange diameter 184mm. Rope to Mean Drum Ratio 10:1 Roller Guides (optional) Heavy duty 4 way commercial type with greaseways. Noise Level 80db Ambient Temp. Operating Range -28 C to 60 C RAMSEY DC34.9 WINCH PERFORMANCE 5

6 WINCH INFORMATION WINCH DIMENSIONS 6

7 WINCH INFORMATION WINCH LABELS 7

8 INSTALLATION WINCH MOUNTING - BEHIND THE CAB Supplied as standard with mounting angles, but can also be mounted on a cradle for above deck. Flush mounting Cut the angles supplied to the correct length as required and weld 6mm plate to each end. Ensure welds are on the inside and outside of the angle and ensure good weld penetration as these are load bearing. Fit two channel or angle members between the first and second cross bearers appropriately spaced to ensure the winch drum is on the centre line of the body. 6mm end plates can then be bolted through these sections using 3 x 10mm high tensile bolts each side with locking nuts. Do not weld the frame in place as the winch must be easily removable in case of damage or repair. Above body floor mounting There are two options available when installing the winch above floor. Option 1 - Using the same procedure as described for flush mounting bolt 6mm extension plates to the 6mm plates welded to the winch angles to raise the winch to the height required. These plates can then be bolted through the angle or channel members as described for flush mounting. 8

9 INSTALLATION WINCH MOUNTING - BEHIND THE CAB Option 2 The DC34.9 can be supplied pre-fitted into a purpose made mounting cradle (Part No. 3689) the winch is fitted with an electronic load limiting device (See page 13). This cradle can be bolted to channel sections spaced between the body cross members with the floor sandwiched between the cradle and the channels. FRONT MOUNTING TO CHASSIS 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. For further advice please contact the chassis manufacturer or dealer. For heavy chassis the winch can 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). 9

10 INSTALLATION ELECTRICAL CONNECTIONS & OPERATIONS Always ensure the correct voltage corresponding to the chassis electrical system is used. If in doubt consult the dealer. For general advice on batteries please see section in the back of this manual. CORRECT ATTENTION TO THE WIRING OF THE WINCH IS ESSENTIAL FOR CORRECT FUNCTIONING AND SAFETY. OLDER MOTOR VERSIONS HAVE EARTHING CONNECTION ON THE END OF THE MOTOR CASING. The basic circuit detail is shown below: Always connect the earth wire from the earth terminal on the side of the motor casing (older motors have the connection on the end of the casing) directly to the battery and not to the chassis. Not only will this prevent a voltage drop to the winch motor but also on a modern chassis this is a requirement to prevent damage to the vehicle electrics and to also ensure a good earth return. The power feed and earth wire cables should be kept as short as possible to avoid voltage reduction to the motor as this will result in reduced puling force and a slower line speed. Ensure that the correct voltage winch is fitted to match the vehicle. POWER SUPPLY CABLES The power feed cables must be rated at 300 amps for 12v and 175 amps for 24v winches. The recommended cable for 12v is 315 strands of 0.40mm diameter per strand and for 24v is 196 strands of 0.40mm diameter per strand. This cable should be as short as possible to run from the batteries to winch power connection to minimise any voltage drop. Recommended cable types: 12v 300a rating use-315 strands of 0.40mm dia./strand. Part Nos: 4096 (Red Sleeve); 4097 (Black Sleeve) 24v 175a rating use-196 strands of 0.40mm dia./strand. Part Nos: 4092 (Red Sleeve); 4091 (Black Sleeve) Available per metre from BHW Group call +44 (0) , or online from 10

11 INSTALLATION ISOLATOR SWITCHES A high amperage isolator switch must be fitted- either: Marine type (left) - Part No Butterfly type (right) - Part No Isolator switch kits include cable boots and rotation label. Available from BHW Group or online at Isolator must be placed so that rotation on/off label is in a clearly visible position. ISOLATOR SWITCH MUST BE TURNED OFF WHEN WINCH IS NOT BEING USED. HEAVY DUTY FUSES (MEGAFUSE) A fuse and fuse holder must be fitted in the positive feed cable as close to the battery as possible to prevent fire risk to the vehicle in the event of a short circuit in the supply cable. These can be purchased separately from BHW Group Limited, or online at Please quote the following part numbers amp Megafuse (for 12v winch) amp Megafuse (for 24v winch) Megafuse Enclosure for above fuses In some circumstances when the vehicle is involved in high usage with only short driving distances between winching operations, it will be necessary to fit an additional heavy duty battery wired in parallel with the vehicle battery and kept as close to the winch as possible. It is also advisable to have the vehicle fitted with a heavy-duty charging system and heavy duty batteries. For battery information please see page

12 INSTALLATION LOAD LIMITING DEVICE The DC34.9 is supplied with a load limiting device that shuts the machine down when the maximum load limit is reached. There are two types of load limiter devices and these are both factory set, but the shut down line pull will not necessarily be accurate due to elasticity in the wire rope and in the vehicle suspension and they may need to be calibrated using the adjusting screws provided and the procedure for each type of load limiter is provided below. For either type of load limiter use a wire rope working on the bare drum with at least seven wraps and the hook connected to an anchor with a dynamometer in the line to measure the load applied. Make sure the battery on the vehicle is fully charged and the engine is running. Apply the load slowly watching the reading on the dynamometer and adjust so the winch cuts out at the machines maximum rating. NOTE: For either load limiting device measuring and testing, please see safety notes at the end of this section (Page 14). Remember drum rotation is counter clockwise viewed from freespool clutch end, when pulling in. If a proof load test is required the setting can be adjusted to achieve the load required and then further adjusted so the winch rating is no greater than the maximum load specified on the plate. The two types of load limiter supplied are described on the following pages. MECHANICAL/ELECTRICAL TYPE This load limiter operates using a microswitch in the end of the worm housing. This is switched by the measurement of the worm movement as it comes under load and sends a signal to switch the control solenoid off. MEASURING THE LOAD SETTING OF THE LOAD LIMITING DEVICE Use a wire rope on the bare drum with at least seven wraps and the hook connected to an anchor with a dynamometer in the line to measure the load applied. Make sure the battery on the vehicle is fully charged and the engine is running. Slowly apply the load by powering the winch using the wanderlead control, whilst monitoring the reading on the dynamometer. STAND WELL AWAY FROM THE LINE OF THE WIRE ROPE AND HOOK IN CASE OF A FAILURE. On a new winch installation a proof load test of 125% of the rated winch capacity should be applied to prove the integrity of the winch and its supporting structure. Following this, further adjustment should be made so that the winch rating is no greater than the maximum load specified on the plate attached to the winch. TO MAKE AN ADJUSTMENT BEFORE ANY ADJUSTMENT IS MADE, THE LOAD MUST BE RELIEVED TO TAKE TENSION OUT OF THE WIRE ROPE IN CASE A FAILURE SHOULD OCCUR. 1) Remove tamper proof compound in threaded hole. Remove top set screw. 2) Loosen bottom set screw approximately 2 turns clockwise. 3) To reduce line pull thread switch assembly IN by turning clockwise. To increase line pull, thread the switch assembly OUT 4) After the desired setting has been achieved, tighten bottom set screw securely. 5) Re install top set screw and tighten securely. Fill threaded hole with potting compound, which must be removed before any future adjustment is made. Details on the Electronic Load Limiting Device can be found on the following two pages. 12

13 INSTALLATION ELECTRONIC LOAD LIMITING DEVICE (Optional) The DC34.9 fitted in an upright bracket, (and also for some other applications), is supplied pre-fitted with an electronic load-limiting device that works by measuring a millivolt change in the power supply. The load limiting device is supplied factory set, but the shut down line pull may not necessarily be accurate for the application due to elasticity in the wire rope and in the vehicle suspension, and may need recalibration. The sections below detail the connection, testing and adjustment of the load limiting device. CONNECTING THE LOAD LIMITNG DEVICE The load limiting device is contained in a sealed / potted container (usually positioned on the underside of the solenoid control) with wires for connection as shown in the diagram below. IMPORTANT NOTE The positive supply cable (Red 170a or 300a depending on voltage of winch) is prefitted, wired into the load limiter. Linked to this are two 1mm wires (Mauve and Red) whose connections to the positive supply cable are set to a calibrated distance between them. This circuit measures millivolt change in supply and determines when the load limiting device will register maximum load and shut down the operation of the winch. This section of the positive supply cable and the attached wires must not be removed or modified in any way, as it will cause the load limiting device to fail to function correctly. The following page shows how to measure and how to adjust the settings for the load limiting device. 13

14 INSTALLATION MEASURING THE SETTING OF THE LOAD LIMITING DEVICE Use a wire rope on the bare drum with at least seven wraps and the hook connected to an anchor with a dynamometer in the line to measure the load applied. Make sure the battery on the vehicle is fully charged and the engine is running. Slowly apply the load by powering the winch using the wanderlead control, whilst monitoring the reading on the dynamometer. STAND WELL AWAY FROM THE LINE OF THE WIRE ROPE AND HOOK IN CASE OF A FAILURE. On a new winch installation a proof load test of 125% of the rated winch capacity should be applied to prove the integrity of the winch and its supporting structure. Following this, further adjustment should be made so that the winch rating is no greater than the maximum load specified on the plate attached to the winch. ELECTRONIC LOAD LIMITING DEVICE ADJUSTMENT BEFORE ANY ADJUSTMENT IS MADE, THE LOAD MUST BE RELIEVED TO TAKE TENSION OUT OF THE WIRE ROPE. Once the load limiter has stopped the winch can be re-set by pressing the OUT button on the wanderlead. Usually a quarter turn of the winch will be sufficient to re-set it for operation. An adjustment screw to enable an accurate load setting is bedded into the outer of the load limiting device. To make an adjustment use a screwdriver and wind in to increase the rating or wind out to reduce the rating. The load limiting device should then be measured again for load tolerance as per instructions above, and this process should continue until the correct calibration is achieved. Following final adjustment, a suitable proprietary compound should be placed in the hole containing the adjusting screw as this will show any tamper evidence on future inspection. 14

15 INSTALLATION WANDERLEAD REMOTE SOCKETS Position female connector to accept wanderlead at convenient point that will avoid damage and water spray. Connect a 3 core 5amp waterproof cable and secure this to avoid chaffing and route to winch position. Fit a male connector to plug into winch socket. Silicon waterproof sealant is recommended around all electrical connectors. BHW optional kits are available for both single and double rear sockets. Part numbers and

16 INSTALLATION EMERGENCY STOP SYSTEM It is a requirement under EN and the Machinery Directive that all machines have Emergency Stops. Whilst BHW Group can offer a comprehensive range of Emergency Stop systems, it is ultimately the responsibility of the person installing the winch to carry out a risk assessment to decide and provide the Emergency Stop suitable for the application. BHW Group Emergency Stop options include: 1. A heavy duty Emergency Stop circuit breaker button that is wired into the main power feed, that when activated cuts the power to the winch. 2. An additional solenoid, that utilises a diode and is energised as soon as either In or Out buttons on the wanderlead are activated. This diode ensures that the vehicle battery will not go flat if the operator forgets to turn off the winch isolator button after use. Emergency Stop circuit breaker button or buttons can be located in the appropriate position for the vehicle application. This system can work in conjunction with the BHW Group FM Connect radio remote system. 3. As No. 2 above but with an additional Emergency Stop circuit breaker button located on the wanderlead handset. 4. A complete control panel incorporating the directional solenoids, Emergency Stop and isolator switch. The control system can then be mounted in the most suitable work area and comes with a full wiring harness. Please contact BHW Group sales to discuss any of these options on TESTING After the installation is complete, a proof load test of 125% of the rated load should be carried out to ensure correct installation before the winch goes into service. To adjust the load limiter to provide the necessary force required see under load limiting devices above after determining the type fitted to the winch. REMEMBER: LOAD MUST BE RELEASED BEFORE ADJUSTING LOAD LIMITING DEVICE. TO TRIAL THE WINCH Turn on isolator switch, plug in wanderlead control. The winch can be powered both In, and Out. The load is automatically held safely when control button is released. The following pages show test procedures for the solenoid and the motor. 16

17 TEST PROCEDURES FOR MOTOR The DC34.9 winch motors are 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 during test procedure (the starting torque of motor is high). Clockwise rotation: Connect a jumper wire (at least a number 25mm sq 170-amp wire) from F-1 to A motor terminals. Attach a wire (at least a number 25mm sq 170-amp wire) from positive (+) battery terminal to F-2 motor the motor and battery terminal. Negative (-) battery terminal to motor earth terminal. Motor should now run. Anti-clockwise rotation: Attach jumper wire from F-2 to (A) motor terminals (See fig. 2). Attach wire from positive (+) battery terminal to F-1 motor terminal. Negative (-) battery terminal to motor earth terminal. NOTE: Always attach battery wire solidly to motor terminals. Make and break the connection of the negative (-) battery terminal at the motor housing. This avoids burning the motor terminals. CAUTION: Do not run the motor for a long period of time in fashion mentioned above, because the motor could become damaged. 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. 65 to 70 amps. If after following the procedure outlined the test on the winch significantly exceeds 70 amperes refer to page 24 for troubleshooting suggestions on the mechanical portion of the winch. See figs. 3 & 3a for the solenoids connection to the motor and the battery. 17

18 TEST PROCEDURES FOR SOLENOID 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 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. Earth the solenoid to the motor with a wire as shown. 5. Attach positive (+) battery wire to the opposite side terminal of the solenoid. Earth 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 should now be running if the solenoid is good. If not, make sure the motor will run directly from the battery. 8. To test the upper contacts use the same hook-up except use the top terminals.(see 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 solenoid 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. 18

19 WIRE ROPE INSTALLATION Unwind rope by rolling it out along the ground behind the vehicle to prevent kinking. Pass fused end through roller fairlead and slide the wire rope through narrow end of the pocket against the drum flange. Wrap the wire rope around the anchor wedge and pull the wire and anchor back into the wide end of the pocket. Use a soft hammer to drive the back of the wire rope firmly seating the wire rope and anchor into the pocket. 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. 19

20 OPERATING INSTRUCTIONS SAFETY PRECAUTIONS PLEASE READ THIS CAREFULLY BEFORE OPERATING THE WINCH. It is important that you read and digest the information contained in this handbook. This Ramsey winch is of the highest quality and has been designed to give a robust and efficient service for many years if care and attention are given at all times to correct, safe operation and maintenance. Respect for a winch and common sense in its operation, will ensure complete safety and reliability. Do not underestimate the potential danger in winching operations. Be aware of the basic dangers so you can avoid risk of accidents and unnecessary damage to the winch or the vehicle / application. 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 puling 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. Take care of the wire rope. Check regularly for signs of wear in the form of broken strands or severe kinks along its length. If there are more than 10 stands broken in any 25mm of the rope's length then it will be significantly weakened and must therefore be replaced. Wear and tear can be prevented by regular application of rope dressing available in aerosol form from your winch supplier. Oil and grease should never be used. Always apply tension to the wire rope (using the safety hook webbing strap attached to the hook) to ensure that the wire rope is rewound neatly and evenly on to the drum. Loose coils or uneven wrapping are dangerous and can result in trapping or snatching when next used - and also damage to the wire rope or the winch. Do not drive the vehicle to pull 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 over the wire rope, halfway along its length. The blanket will reduce the speed of a snapped rope. When recovering a vehicle, the winch hook should be attached to the towing hitch, if available, or to a strap or chain around a chassis leg or cross member. NEVER anchor the winch hook onto bumpers, or shipping / transit anchorage. Do not allow the load to 'snatch' during a pull, as this can momentarily double or even treble the load on the rope. Try to position either your vehicle or the anchor point to ensure as straight a pull as possible. Use a snatch block if it is necessary to turn any corners with the rope. When attaching the hook to the load, always double check that the hook is secure and the safety catch is fully closed. Remember that if the hook breaks away under tension, serious injury can result, as the hook will travel through the air at speed. A minimum of five wraps of rope around the drum is recommended to hold the load. NEVER hold the safety hook to rewind the winch use the safety hook webbing strap provided. 20

21 OPERATING INSTRUCTIONS 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 plane. As in the case of all winches, this refers to the first layer of rope on the drum. In most cases, when the winch is being used, there is no way of accurately determining the exact pull being applied. It is important, however, to try and establish that it is within the working capacity of both the winch and wire rope and this can be done by considering the following formulae which applies for gradients up to an angle of 45. For wheeled vehicles, the pull required to move the load equals: W + (W x angle of gradient) Where W = load in tonnes and angle of gradient is in degrees. EXAMPLE If W, the load of the vehicle is 4 tonne and is being pulled up skids, which form a gradient of 18, the force on the rope is: 4 + (4 x 18) = = 1.36 tonne Remember the winch pulling capacity reduces as the number of layers of wire rope increase on the drum. 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. TO OPERATE WINCH Operator familiarisation: Operators must first become familiar with the winch operating system with no loading applied. Turn on isolator switch, plug in wanderlead control. The winch can be powered both in and out. The load is automatically held safely when control button is released. The best way to become acquainted with how your winch operates is to make test runs. Plan your tests in advance. Remember that you hear your winch as well as see it operate. Come to recognise the sounds of a light steady pull, heavy pull, and sounds caused by load jerking or shifting. Gain confidence in operating your winch and its use will become second nature to you. The uneven spooling of wire rope whilst pulling a load, is not a problem, unless there is a pile up of rope on one end of the drum. If this happens, reverse the winch to relieve the tension on the rope and move your anchor point further to the centre of the load. After the job is complete, you can unspool and rewind the wire rope neatly. Always switch of the isolator switch after use and always use the webbing strap attached to the safety hook when rewinding rope back onto the drum to prevent potential injury to hands from the roller guide. 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. Ensure that handle is fully engaged before imposing load on winch. CAPACITIES The Ramsey DC34.9 winch is rated at 3558kg (34.9kN), and this refers to its safe working load, measured as the force being applied to the winch in a horizontal place. As in the case of all winches, this refers to the first layer of rope on the drum. 21

22 MAINTENANCE REGULAR MONTHLY MAINTENANCE Externally: The winch should be kept clean in order to prevent any build up of corrosion on external working parts. Inspect roller guides for grooving and if excessive, wire rope life will be reduced. Worn guides should be replaced to ensure wire rope is not damaged. Check winch for external damage. Check winch mounting for distortion and re-tighten mounting bolts if necessary. Operate free spool clutch mechanism to ensure correct operation, giving full engagement and disengagement. All external-moving parts should be lubricated with lightweight oil. All Electrical connections and wiring should be inspected for loose connections, corrosion or fretting. Check the tie bars that hold the winch in alignment replace if bent or broken. Check the emergency STOP control to ensure it functions correctly by operating the winch and pushing the STOP button. Check oil level in gearbox and replenish with EP90 gear oil. ANNUAL MAINTENANCE In addition to the maintenance detailed above, change the oil in winch gearbox and spur box. Refill to oil level plugs. OIL TYPES: For worm and wheel gearbox: EP90 For spur gearbox: SAE20 SPARES If it becomes necessary to obtain replacement parts, refer to diagram and list shown on pages 21 and 22 for the winch, and page 23 for the solenoid.. Please contact us quoting serial numbers and model number. BHW Group Limited reserve the right to change specifications without notice. CARE OF THE WIRE ROPE It is most important that the wire rope is inspected on a regular basis, for kinks, flat spots, broken strands and other damage, and if necessary the damaged sections should be cut away and the rope reattached or completely replaced. Check both the rope and the hook and replace under any of the following circumstances: 10 strands of rope or more broken with a space of 25mm. Rope shows visible signs of wasting. Deformed or excessively corroded rope. Twisted rope. Bent rope. A good habit is to rewind the rope onto the winch drum after it has been used, so that it is evenly layered. To do this, rewind keeping the rope under tension. Normally the load can be applied by hand. Under no circumstances wrap the wire rope around the load being recovered and then attach the hook back on to the rope. This will result in serious rope damage or breakage. Always employ a chain or webbing strap from the hook to the load. Wire rope and hook must be replaced if damaged. If the winch is not being used on a regular basis it should be powered in and out from time to time to minimise corrosion of the internal motor components that may occur due to condensation. Energising the motor will generate heat, which will help dissipate any moisture. WIRE ROPES ARE NOT COVERED BY WARRANTY. 22

23 WINCH PARTS PARTS DIAGRAM 23

24 WINCH PARTS PARTS LIST Item Qty Item No. Description Item Qty Item No. Description SWITCH ASSEMBLY - 12FT LG WASHER 1/4 FLAT ALUMINIUM H/D SWITCH ASSEMBLY - 12FT LG (OPTION) LOCK WASHER 3/8 MED SECT Z/P E/STOP SWITCH KIT 12v (NOT SHOWN) DRAG BRAKE E/STOP SWITCH KIT 24v (NOT SHOWN) GASKET MOTOR 12v GASKET MOTOR 24v GASKET SHIFTER ASSEMBLY KEY SOLENOID ASSEMBLY 24v KEY SOLENOID ASSEMBLY 12v BARTH KEY ASSEMBLY WIRE - BATTERY CABLE - RED BARTH KEY ASSEMBLY WIRE - GROUND - BLACK LUBE FITTING NAME & DATA PLATE RELIEF FITTING JAW CLUTCH O - RING COVER - SPUR GEAR HOUSING REDUCER COVER - GEAR HOUSING PIPE PLUG DRUM ASSEMBLY STANDARD PIPE PLUG DRUM ASSEMBLY "Y" PIPE PLUG IDLER GEAR DOWEL PIN SPUR GEAR SPIROL PIN PINION GEAR PLUG GEAR RH - 60: PLUG GEAR RH - 46: BOOT SHIFTER HANDLE OIL SEAL HOUSING - SPUR GEAR OIL SEAL HOUSING - CLUTCH OIL SEAL HOUSING - GEAR SNAP RING KEY SPRING SHAFT - SPUR SPRING SHAFT - DRUM STANDARD THRUST WASHER SHAFT - DRUM "Y" THRUST WASHER WORM RH 60: THRUST WASHER WORM RH 46: FIBRE WASHER BALL BEARING SWITCH ASSEMBLY BUSHING BEARING CAP BUSHING CAP SCREW BUSHING SET SCREW CAP SCREW 1/4-20NC x ¾" HX HD GR5 Z/P O - RING CAP SCREW 1/4-20NC x 1" HX HD GR5 Z/P THRUST ACTUATOR CAP SCREW 1/4-20NC x 1" HX HD GR5 Z/P THRUST DISC CAP SCREW 3/8-16NC x ¾" HX HD GR ANGLE - STANDARD CAP SCREW 1/4-20NC x 1" HX SOC HD - NYLOK ANGLE "Y" CAP SCREW 1/4-20NC x ¾" HX SOC HD Z/P ANGLE - STANDARD SET SCREW 1/4-20 x 5/16" HX SOC - ND STRIP ANGLE "Y" SET SCREW 1/4-20 x 3/8" HX SOC FULL DOG PT CAP SCREW 3/8-16NC x 1¼"LG HX HD ROPE ANCHOR CAP SCREW 3/8-16NC x 5/8"LG HX HD 24

25 WINCH PARTS SOLENOID PARTS DIAGRAM & LIST Item No. Qty. Ramsey No. BHW Item No. Description CABLE BOLT ASSEMBLY 12v 5062 CABLE BOLT ASSEMBLY 24v WIRE ASSEMBLY WIRE ASSEMBLY STRAP STRAP SOLENOID BRACKET SCREW SCREW NUT NUT 3/16-18NC HX REG FLAT WASHER No LOCK WASHER 5/16 MED SECT ZINC SHAKE PROOF WASHER 5/16 INTERNAL SHAKE PROOF WASHER 5/16 EXTERNAL FEMALE CONNECTOR TERMINAL - TAB SOLENOID 12v SOLENOID 24v SOLENOID COVER COVER - CONNECTOR COVER - TERMINAL 25

26 TROUBLE SHOOTING CONDITION POSSIBLE CAUSES CORRECTIONS Clutch inoperative or binds up. 1) Dry or rusted shaft. 2) Bent yoke or linkage. 1) Clean and lubricate. 2) Replace yoke or shaft assembly. 3) Clutch jaws are in contact. 3) See techniques of operation. Oil leaks from housing Cable drum will not freespool 1) Seal damaged or worn. 2) Too much oil. 1) Winch not mounted squarely, causing end bearings to bind drum. 1) Replace seal 2) Drain excess oil. Refer to techniques of operation. 1) Check mounting, refer to winch mounting Page 6 Wire rope bird nests when clutch is disengaged 1) Drag brake disc worn. 1) Replace discs. Motor runs in one direction only 1) Inoperative solenoid or stuck solenoid. 2) Inoperative switch 3) Broken wire or bad connection. 1) Jar solenoid to free contacts. Check by applying 12volts to coil terminal (it should make an audible click when energised). 2) Disengage winch clutch or remove armature lead. Remove switch plug from hood. Raise connector cover on hood with screwdriver, short the two bottom pins. Solenoid should click. Short the two left hand pins. The other solenoid should operate. If both solenoids operate, check for broken wire in switch cable. 3) Check for loose connection on switch and switch connector. Motor runs extremely hot 1) Long running period at high loading.. 2) Damaged motor 3) Damaged brake 1) Cooling-off periods are essential to prevent overheating 2) Replace motor 3) Replace brake Motor will not operate Motor runs but with insufficient power or line speed Motor runs but drum doesn t turn 1) Isolator switch not turned on. 2) Fuse has blown. 3) Break in power lead or extension socket. 4) Inoperative solenoid or stuck solenoid. 5) Inoperative switch 6) Inoperative motor 7) Loose connections 1) Weak Battery 2) Battery to winch power lead too long creating voltage drop 3) Poor battery condition 4) Poor earth connection 5) Damaged brake 6) Poor isolator switch condition Clutch not engaged Drive shaft damage 1) Turn on isolator switch. 2) Replace fuse. 3) Repair or replace wiring. 4) Jar solenoid to free contacts. Check by applying 12volts to coil terminal (it should make an audible click when energised) 5) Disengage winch clutch or remove armature lead. Remove switch plug from hood. Raise connector cover on hood with screwdriver, short the two bottom pins. Solenoid should click. Short the two left hand pins. The other solenoid should operate. If both solenoids operate, check for broken wire in switch cable. 6) If solenoids operate, check for voltage at armature post, replace motor. 7)Tighten connections on bottom side of hood and on motor. 1) Recharge or replace battery. Check charging system 2) Check correct amperage cable and/or reduce length 3) Check battery terminals for corrosion. Clean as required 4) Check and clean connection Cable should earth to battery not chassis. 5) Repair or replace brake 6) Repair or replace isolator switch Engage clutch Repair or replace drive shaft 26

27 OVERHAUL INSTRUCTIONS NOTE: DIAGRAM NUMBERS ARE NOT PART NUMBERS PLEASE SEE PAGES DIS-ASSEMBLY 1. Drain oil from worm gear housing by removing (item 54) plug from bottom of gear housing. Remove relief fitting and reducer (items 50 & 53) from top of gear housing. Remove mounting angles (items 4 & 5) from winch by removing hardware shown. 2. Drain oil from spur gear housing by removing (item 54) plug. Remove cover and gasket (items 9 & 44) from spur gear housing by unscrewing twelve capscrews (item 28). Slide gear (item 12) from end of worm shaft (item 23). Remove spur gear shaft (item 21), with gears attached. Check bearings (item 24) 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 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 lock washers (items 39 & 41). Unscrew (4) capscrews (item 34) to remove spur gear box (item 16) 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. 4. Slide clutch housing (item 17) from end of drum shaft. Slide jaw clutch (item 7) from end of drum shaft. Remove (2) keys (item 47) from keyways. A screwdriver can be used, at notch, to aid in removal of keys. Once keys have been removed, drum (item 10) 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. 27

28 OVERHAUL INSTRUCTIONS NOTE: DIAGRAM NUMBERS ARE NOT PART NUMBERS PLEASE SEE PAGES Remove bearing cap (item 6) from gear housing by unscrewing four capscrews (item 29). Remove worm (item 23) and bearing (item 25) 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 23) and bearings (item 25). Replace if necessary. 6. Remove gear housing cover (item 8) from gear Housing (item 18) by unscrewing five remaining capscrews (item 28). 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 22), 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 14) from shaft (item 22). 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 48) into keyways. Press gear (item 14) over shaft and keys. Gear must be centred over keys. 8. Remove seal (item 63) from back of gear housing (item 18). Check bushing (item 27) for signs of wear. Press bushing (item 27) from gear housing and replace if necessary. Press new bushing and seal back into place. 28

29 OVERHAUL INSTRUCTIONS NOTE: DIAGRAM NUMBERS ARE NOT PART NUMBERS PLEASE SEE PAGES 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 shaft. Replace if necessary by removing pin (item 58) from handle (item 15). Remove rubber plug (item 59) from housing. Unscrew setscrew enough to allow shifter assembly to be removed from housing. Check clutch housing bushing (item 26) for signs of wear. Remove if necessary by pressing old bushing from housing (item 17) and pressing 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 handle (item 15) 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 8) 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 gear (item 13), o-ring (item 52) and fibre washer (item 71) as follows: b. Place fibre washer (item 71) and well oiled o-ring (item 52) over end of motor shaft and down to bottom of shaft. b. Insert key (item 46) into motor shaft keyway. Slide pinion gear over shaft and key. Use a hammer and 22mm (internal diameter) 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 46mm distance from top of gear to cast surface below gear. Tighten setscrew (item 36) securely enough to prevent pinion gear from moving on motor shaft. 13. Check gears of spur gear shaft assembly for signs of wear, replace if necessary. Press old gears from shaft (item 21). Tap key (item 20) into keyway of shaft (item 21). Press shaft through gears so that gears are centred on shaft and key. 29

30 OVERHAUL INSTRUCTIONS NOTE: DIAGRAM NUMBERS ARE NOT PART NUMBERS PLEASE SEE PAGES RE-ASSEMBLY 14. Apply 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 70) and bushing in gear housing (item 18). Place gasket (item 45) onto gear housing cover (item 8). Apply grease to gear end of shaft and bushing in cover. Place cover onto shaft and secure to housing with five capscrews (item 28) 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 downwards 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 (item10). 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 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. 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 7) over end of shaft and slide jaw clutch over keys. Set clutch housing (item 17) over end of drum shaft. Pull jaw clutch (item 7) upward, toward clutch housing, enough to allow yoke, in clutch housing, to fit properly in groove around jaw clutch. 30

31 OVERHAUL INSTRUCTIONS NOTE: DIAGRAM NUMBERS ARE NOT PART NUMBERS PLEASE SEE PAGES Press bearing (item 24) onto worm (item 23). 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 43) onto bearing cap (item 6). Use four capscrews (item 29) to secure cap to gear housing. Torque capscrews to 7 ft-lbs. (9.4 Nm) each. Attach solenoid assembly (item 2) to gear housing. Use two (item 34) capscrews and three (item #30) 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 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). Torque capscrews to 7 ft-lbs. (9.4 Nm) each. Mount motor (item 51) to spur gear housing (item 16) 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 23) and set into snap 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 (item12) and (item 68) thrust washer over end of worm shaft (item 23). Insert pins (item 57) into cover (item 9). Place gasket (item 44) onto cover. Attach cover and gasket to spur gear housing using twelve capscrews (item 28). 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 50 & 53) from top of spur gear housing. Pour 0.24 litres (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 4 & 5) using six Capscrews (items 32) with lockwashers and capscrews (items 35 & 31). 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 0.35 litres (3/4 pt) of E.P. 140 gear oil into housing through hole in top of housing. Insert relief fitting (item 50) into reducer (item 53). Reducer should then be placed into hole on top of gear housing. Tighten fitting and reducer securely. 31