OPERATING, SERVICE AND

MAINTENANCE MANUAL

MODEL DC-200 SERIES

LEVER EQUIPPED
INDUSTRIAL LOW-MOUNT
WINCHES
INCLUDES: DC-200/DC-246, DC-24-200/DC-24-246.
DCY-200/DCY-246, DCY-24-200/DCY-24-246
AND MODELS EQUIPPED WITH OPTIONAL ADJUSTABLE, AUTO-
MATIC OIL COOLED SAFETY BRAKE: DCG-200, DCYG-200 SERIES
WINCHES.

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND

OPERATION OF WINCH. SEE SAFEGUARDS AND WARNINGS!
 TABLE OF CONTENTS

INTRODUCTION ............................................................................ 1

WARRANTY INFORMATION .......................................................... 1

SPECIFICATION .............................................................................. 1

TECHNIQUES OF OPERATION ................................................... 2

WARNINGS ...................................................................................... 2

WINCH MAINTENANCE ................................................................. 3

WINCH MOUNTING ......................................................................... 4

ELECTRICAL CONNECTIONS .................................................... 4

CABLE INSTALLATION .................................................................. 4

ADJUSTING THE OIL COOLED SAFETY BRAKE...................... 4-5

SERVICING OF THE OIL COOLED SAFETY BRAKE................ 5

RE-ASSEMBLING AND CHECKING THE BRAKE...................... 6

TEST FOR PROPER BRAKE ASSEMBLY.................................. 6

INSTRUCTIONS FOR CHECKING ASSEMBLY

ARRANGEMENT AND SETTING OF WORM BRAKE............... 7

TROUBLE SHOOTING GUIDE........................................................ 8-9

INSTRUCTIONS FOR OVERHAUL OF

RAMSEY MODEL DC-200 SERIES LEVER WINCHES
DISASSEMBLY........................................................................ 10-13
REASSEMBLY......................................................................... 13-16

DIMENSIONAL DRAWING.............................................................. 17

PARTS LIST AND PARTS DRAWING........................................... 19-20

SOLENOID AND SWITCH ASSEMBLY PARTS LIST................. 21

TEST PROCEDURE FOR SOLENOID......................................... 22

TEST PROCEDURE FOR MOTOR............................................... 23

MOTOR PARTS REPLACEMENT ................................................ 24

LIMITED WARRANTY....................................................................... 26
 RAMSEY ELECTRICAL WINCH MODEL DC-200 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-ad-
dressed postage paid warranty card. Please read and fill out the enclosed warranty card and send it
to Ramsey Winch Company. If you have any problems with your winch, please follow instructions for
prompt service on all warranty claims. Refer to back page for limited warranty.
SPECIFICATIONS: Conforms to SAE J706
Rated Line Pull 1st Layer (lbs.) .......................................................................................................... 8,000
(kgs.) .......................................................................................................... 3,630
Total Gear ReducƟon: DC-200........................................................................................................... .... 470
DC-246.............................................................................................................. 360
Weight: DC-200/0C-246 (long drum)............................................................................... 116 lb. (52.6 Kgs.)
DCY-200/DCY-246 (short drum) ........................................................................ 105 lb. (47.6 Kgs.)
MAXIMUM GEAR BOX OIL TEMPERATURE SHOULD NOT EXCEED.......................................................... 250°F
Layer of Cable 1 2 3 4
Rated Line Pull Lbs. 8,000 6,700 5,700 5,000
per layer Kgs. 3,620 3,030 2,580 2,260
Long Drum Cable Ft. 25 60 90 140
capacity per layer M. 7 18 28 42
Short "Y" Drum
cable capacity Ft. 15 30 55 75
per layer M. 4 9 16 22
NO LOAD 2000# LOAD 4000# LOAD 8000# LOAD
Line Speed FPM FPM FPM FPM
VOLTS (MPM) AMPS (MPM) AMPS (MPM) AMPS (MPM) AMPS
DC-200/DCY-200 12 14 65 7 110 5 180 3.5 280
DC-24-200/DCY-24-200 24 (4.3). 30 (2.1). 50 (1.5). 90 (1.1). 140
DC-246/DCY-246 12 16.5 70 8.5 140 5.5 200 3.5 330
DC-24-246/DCY-24/246 24 (5) 35 (2.5). 70 (1.7) 100 (1.1). 160

*These specifications are based on recommended 3/8 inch dia. extra improved
plow steel wire rope or equivalent.
Winch only conforms to SAE J706. For SAE qualification of mounting angles,
if applicable, consult Ramsey Engineering.
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.

DUTY CYCLE
Winch duty cycles are shown below:
6 5

5 4
4
3
MINUTES
MINUTES

3
2
2
1
1

0 0

180 270 360 90 120 160 190

AMPS
AMPS
12 V 24 V

1
 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 shift-
ing. Gain confidence in operating your winch and its use will become second nature with you.
The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pileup on
one end of drum. If this happens, reverse the winch to relieve the load and move your anchor point
further to the center of the vehicle. After the job is done you can unspool and rewind for a neat lay of
the cable.
When pulling a load where there is even a remote chance of cable failure, place a blanket, jacket
or tarpaulin over the cable about six feet behind the hook. This will slow the snap back of a broken
cable and could prevent serious injury.
Check oil level of winch every six months. Replace oil annually or more often if winch is used fre-
quently. Use 3/4 pint of all purpose EP 140 oil in the worm gear housing and 1/2 pint SAE 20 for spur
gear box. If the oil is contaminated with metallic particles, inspect winch for cause of abnormal wear.
Periodically check all electrical connections and mounting bolts. Tighten hardware if necessary.
The minimum ampere-hour rating of vehicle battery should be 70, and used with at least a 40 amp
alternator. An Auxiliary battery is recommended to supply additional battery power. Inspect the cable
frequently. If the cable becomes frayed with broken strands, replace immediately. Cable and hook
assembly may be purchased from a Ramsey distributor. The winch clutch allows rapid unspooling of
the cable, from cable drum, for hooking onto a load. The clutch is operated by the lever located on
the clutch housing of winch.
1. TO DISENGAGE CLUTCH, run the winch in the reverse (reel out) direction until load is off the
cable. Grasp lever and push toward drum to the “OUT” position. The lever is latched “OUT” by ball
and detent in jaw clutch and drum shaft. The cable may now be pulled from cable drum by hand.
2. TO ENGAGE CLUTCH, pull handle away from drum to the “IN” position, while rotating drum, until
clutch jaws engage with drum jaws. CLUTCH MUST BE TOTALLY ENGAGED DURING WINCH-
ING OPERATION. The lever is latched “IN” by ball and detent in jaw clutch and drum shaft. The
plastic plug in top of clutch housing may be removed, for inspection of clutch, to assure total en-
gagement.

WARNINGS:
CLUTCH MUST BE TOTALLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
DO NOT LEAVE CLUTCH ENGAGED WHEN WINCH IS NOT IN USE.
STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS.
STAND CLEAR OF CABLE WHILE PULLING. DO NOT TRY TO GUIDE CABLE. DO NOT EXCEED
MAXIMUM LINE PULL RATINGS SHOWN IN TABLE.
DO NOT USE WINCH TO LIFT. SUPPORT, OR OTHERWISE TRANSPORT PERSONNEL.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE
LOAD. CABLE CLAMP IS NOT DESIGNED TO HOLD LOAD.
DISCONNECT THE REMOTE CONTROL SWITCH FROM WINCH WHEN NOT IN USE. A RAMSEY
PART NO. 282053 SAFETY ON-OFF SWITCH IN YOUR VEHICLE IS RECOMMENDED.
2
 WINCH MAINTENANCE

Adhering to the following maintenance schedule will keep your winch in top condition and perform-
ing 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. Lubricate the various grease fittings located in the cable drum, end bearing, clutch housing or
clutch operating linkage. Any good grade of moly-disulfide containing grease is acceptable.
2. Check the action of the sliding clutch, making sure it is fully engaging and disengaging with the
cable drum. Remove the plastic plug in top of the housing and observe if the clutch is fully en-
gaging. If clutch is not fully engaging, inspect clutch shifter assembly parts, check for damage
or excessive wear and replace as necessary. Observe the jaws on both the clutch and cable
drum, checking for rounding of the driving faces. If rounding has occurred they should be re-
placed immediately.
3. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that
are loose. Make sure to use only grade 5 bolts or better.
4. Check the torque setting of the oil cooled worm brake. Make any adjustments required, fol-
lowing the procedure described in ADJUSTING THE OIL COOLED WORM BRAKE in the
Owner’s Manual.
5. Check alignment of chain and sprockets and adjust as required to minimize wear.
6. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.

C. ANNUALLY

1. Drain the oil from the winch annually or more often if winch is used frequently.
2. Fill the winch to the oil level plug with clean kerosene. Run the winch a few minutes
with no load in the reel in direction. Drain the kerosene from the winch.
3. Refill the winch to the oil level plug with all purpose EP 140 gear oil.
4. Inspect frame and surrounding structure for cracks or deformation.
5. Gear wear can be estimated by rocking the drum back and forth and if necessary
drain oil and remove cover for closer inspection.

3
 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 17. Using a power cable with appropriate end terminals, con-
nect the positive (+) battery terminal to the 5/16” dia. stud on the plastic solenoid cover on the
winch. IMPORTANT: Hold inner nut on stud with a wrench while tightening outer nut. Using a
ground cable with appropriate end terminals, connect the negative(-) battery terminal to the mo-
tor isolated ground terminal. In applications where the chassis is non-grounded, a jumper wire
(#440315) will be required between the winch and the motor ground. This ground is required to
insure a sufficient ground to operate the solenoid assembly (See Diagram Below). For distances up
to 15 feet from battery to winch, use #2 Ga. wire for the above connections. For distances greater
than 15 feet, use wire larger than #2 Ga.

WINCH WILL NOT OPERATE UNLESS

GROUND CABLE IS INSTALLED FROM THE
ISOLATED GROUND TERMINAL TO THE
NEGATIVE BATTERY POST.
(SEE DIAGRAM BELOW)

SEE ILLUSTRATION
BELOW

NEGATIVE BATTERY POST

JUMPER CABLE (#440315) MUST BE

INSTALLED ON WINCH FROM MOTOR
ISOLATED GROUND STUD TO GEAR
HOUSING COVER BOLT AS SHOWN
ISOLATED GROUND FOR NON GROUNDED CHASSIS
APPLICATIONS.
TERMINAL

GROUND CABLE
For non-grounded chassis applications
a jumper wire (#440315) is required to
Isolated Motor Ground
ground the solenoid assembly.
CABLE INSTALLATION
1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of cable,
opposite hook, with plastic or similar tape to prevent fraying.
2. Insert the end of cable, opposite hook end, into the 7/16” dia. hole in drum barrel. Secure cable to
drum barrel, using setscrew furnished with winch. TIGHTEN SETSCREW SECURELY.
3. Carefully run winch in the “reel-in” direction. Keeping tension on end of cable, spool all the cable
onto the cable drum, taking care to form neatly wrapped layers.

ADJUSTING THE OIL COOLED WORM BRAKE

The oil-cooled, fully adjustable, automatic safety brake operates in the worm housing lubricant, all
parts being submerged in oil. When the brake wears to the point that the load begins to drift, the
brake can be adjusted as follows:
1. Loosen the lock nut on the adjusting screw.

4
2. Tighten the brake by turning the adjusting screw clockwise. CAUTION: Only 1/4 turn is usually
required to adjust the brake. Over-tightening can cause overheating and damage to the
brake parts. Tighten the lock nut after adjustment is completed.
If the brake does not respond to adjustment, then a new leaf spring and brake disc is needed.
A torque wrench can be equipped with a special adapter to fit the input shaft (worm) of the winch.
The adapter can be made by welding a nut to the end of a piece of tubing as shown in the follow-
ing figure. After welding the cap and nut to the tubing, slot the tubing as shown. This will allow
the special adapter to slide over the keyway and will then act as a large socket. A torque wrench
can then be used to apply the proper torque. Turn the torque wrench so that the drum turns in the
spool out direction or lowering direction. The torque rating for the Model 200/246 should be 8 to
13 ft. lbs. (D-200, 13 to 18 ft.-lbs.). If the torque wrench does not show the proper value as it turns,
then the worm brake adjusting bolt should be turned clockwise 1/4 turn. Each time the adjusting
bolt is turned, check the torque reading. Continue this procedure until the proper torque reading is
achieved. Then tighten the lock nut.

SERVICING OF THE OIL COOLED SAFETY BRAKE

1. Remove the drain plug and drain the worm gear oil from the worm housing.
2. Back off the lock nut, then the adjusting screw, both two turns or more by turning them
counter-clockwise.
3. Remove the cover mounting screws.
4. Remove the cover along with coil spring and leaf spring.
5. Remove the retainer plate, composition brake disc, cam plate and balls.
Note, the slots the balls are in.
6. Inspect parts as follows:
a). Composition brake discs are 1/8” thick when new. Replace if thinner than 0.080” or if
surfaces are glazed or burnt.
b). Inspect the flat, ground surface of the cam plate and retainer plate for glazing, warpage, or
other damage. Glazing can be removed by scraping carefully.
c). Inspect the leaf spring. It should be bowed 1/8”.

5
 BRAKE - CHECKING / RE-ASSEMBLY AND TESTING

RE-ASSEMBLING AND CHECKING THE BRAKE

1. Press brake hub into place over worm shaft and key.

2. Assemble ball into appropriate slots of cam. (Refer to diagram 1, page 5). Use stiff grease to
hold balls into place and slide cam over end of worm. Be sure that balls are secure,
between cam slots and hub slots. Refer to Page 7 to determine proper ball slot setting.

3. Install brake disc.

4. Install retainer plate, smooth side toward brake disc.

5. Install the gasket on the cover with a small amount of grease or sealer.

6. The coil spring goes over the adjusting screw on the inside of the cover.

7. Install the notches of the leaf spring on the pins protruding through the cover.
The hollow side of the leaf spring goes toward the brake.

8. Install brake housing cover, making sure the protruding pins go through the leaf spring and
into the holes in the retainer plate.

9. Bolt cover into place with the mounting screws. Install drain plug and add 1 pint all purpose
E.P. 140 oil.

10.Turn winch in the hoisting direction at least one turn of the input shaft.

11.Turn the adjusting screw in until it is finger tight.

TEST FOR PROPER BRAKE ASSEMBLY

After the brake has been adjusted to the proper torque setting, disengage clutch. Start vehicle
engine and run winch in the reel in (hoisting direction). Allow winch to run in this direction for
one minute.

Place your hand on the safety brake housing. If housing is not hot to the touch then run winch
in the reverse direction (cable out) for one minute. Brake housing should begin to heat.

When these conditions exist, proper installation has been made. If heating becomes noticeable
when running the winch in forward rotation (hoisting direction), the brake should be again dis-
assembled. When disassembled, place the brake balls in the alternate set of slots in the cam
plate, then carefully follow the instructions for re-assembling and checking the brake.

6
 INSTRUCTIONS FOR CHECKING ASSEMBLY ARRANGEMENT
AND
SETTING OF WORM BRAKE

When the worm brake is assembled, the brake must be set with the balls in the #1 or the #2 set of
cam slots. (View A-A, page 5). It is indicated on the name plate whether the balls were installed in
the #1 or the #2 slots at the factory.

Three factors determine which slots the balls should be in:

1. Direction cable winds on the drum. It normally WINDS OVER THE TOP of the drum barrel.

2. The side of the winch that the input shaft is on. The INPUT SHAFT IS NORMALLY TOWARD
THE CAB. Whether the winch has the gear box on the right or on the left side of the winch
does not affect the brake setting.

EXAMPLE: When cable winds over the top of the drum, winch has a right cut gear and input shaft
is toward the cab (diagram 2), then the balls need to be in the #2 cam slots.

If any one of these three factors differ from those stated above, the balls need to be in the #1 slots
in the cam. A second change in these factors requires the original arrangement, and if all three fac-
tors are different, the balls need to be in the #1 slots. (See page 5 and 6 for disassembly and
assembly instructions).

7
 TROUBLE SHOOTING GUIDE

CONDITION POSSIBLE CAUSE CORRECTION

CLUTCH INOPERATIVE OR BINDS 1. Dry or rusted shaft. 1. Clean and lubricate.
UP. 2. Bent yoke or linkage. 2. Replace yoke or shaft
assembly.
3. Clutch jaws are in 3. See TECHNIQUES OF
contact. OPERATION.

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.

LOAD DRIFTS DOWN. 1. Safety brake has 1. Replace brake disc. (See
become worn. Page 5, Diagram 1).
2. Safety brake out of 2. Turn adjusting bolt clock-
adjustment. wise 1/4 turn or until
load does not drift.

CABLE DRUM WILL NOT FREE 1. Winch not mounted 1. Check mounting. Refer to
SPOOL. squarely, causing end WINCH MOUNTING Page 4.
bearings to bind drum.
CABLE BIRDNESTS WHEN CLUTCH 1. Drag brake disc worn. 1. Replace discs.
IS DISENGAGED.

MOTOR RUNS IN ONE DIRECTION 1. Inoperative solenoid 1. Jar solenoid to free

ONLY. or stuck solenoid. contacts. Check by applying
12 volts to coil terminal (it
should make an audible
click when energized).
2. Inoperative switch. 2. Disengage winch clutch or
remove armature lead.
Remove switch plug from
hood. Raise connector cover
on hood and with a screw
driver, short the bottom
two pins. Solenoid should
click. Short the two left
hand pins. The other
solenoid should operate.
If both solenoids operate
check for a broken wire in
switch cable.

3. Broken wire or bad 3. Check for loose connection

connection. on switch and switch
connector.

MOTOR RUNS, BUT DRUM DOES 1. Clutch not engaged. 1-4. If clutch engaged but
NOT TURN. symptom still exists, it
will be necessary to dis-
assemble winch to
determine cause and repair.
2. Sheared drum shaft key.
3. Stripped bronze gear.
4. Parted shaft.

8
 CONDITION POSSIBLE CAUSE CORRECTION

MOTOR RUNS EXTREMELY HOT. 1. Long period of operation. 1. Cooling-off periods are
essential to prevent over-
heating.
MOTOR RUNS, BUT WITH 2. Insufficient battery. 2. Check battery terminal
INSUFFICIENT POWER, OR WITH voltage under load. If 10
LOW LINE SPEED. volts or less, replace or
parallel another battery
to it at motor terminal.

3. Electrical cables from 3. Must be #2 Ga. wire for

battery to winch too small distances up to 15 feet from
battery to winch. Use larger
than #2 Ga. for distances
greater than 15 feet.

4. Bad electrical 4. Check all connections for

connections. looseness or corrosion;
Tighten, clean and grease.
5. Insufficient charging 5. Replace with larger
system. capacity charging system.
MOTOR WILL NOT OPERATE. 1. Inoperative solenoid 1. Jar solenoid to free
or stuck solenoid. contacts. Check by applying
12 volts to coil terminal
(it should make an audible
click when energized).
2. Inoperative switch. 2. Disengage winch clutch or
remove armature lead. Re-
move switch plug from hood.
Raise connector cover on
hood and with a screw
driver, short the bottom
two pins. Solenoid should
click. Short the two left
pins. The other solenoid
should operate. If both
solenoids operate, check
for a broken wire in
switch cable.

3. Inoperative motor. 3. If solenoids operate,

check for voltage at
armature post; replace motor.

4. Loose connections. 4. Tighten connections on

bottom side of hood and on
motor.

9
 INSTRUCTIONS FOR OVERHAUL OF RAMSEY
MODEL DC-200 SERIES LEVER
DIS-ASSEMBLY

1. Drain oil from gear housing by removing

(item #60) plug from bottom of gear
housing. Remove relief fittings and reducer
(items #56 & #59) from top of gear housing.
Remove mounting angles (items #3 & #4)
from winch by removing hardware shown.

2. Drain oil from spur gear box by removing (item

#60) plug. Remove cover and gasket (items #8 &
#50) from spur gear housing by unscrewing bev-
eled capscrews (item #32). Slide gear (item #11)
from end of worm shaft (item #25). Remove spur
gear shaft (item #22), with gears attached. Check
bearings (item #28) and thrust washers (item#72)
for signs of wear, replace if necessary. Remove
old bearings and press new bearings into place.
Remove solenoid assembly (item #1) by
unscrewing capscrews (items #34 & #38).
Disconnect solenoid cables from motor ( item
#57). Make note of which terminals cable are
attached to.

3. Remove key (item #18) and snap ring (item

#69) from worm shaft. Remove motor (item
#57) from spur gear housing (item #15) by
removing (3) nuts and lockwashers (items
#45 & #47). Unscrew (4) capscrews (item
#37) to remove spur gear box ( item #15 )
and gasket (item #49) from gear housing.
Replace lip seals (items #66 & #68) by
pressing old seals from spur gear housing
and pressing new seals into place.

10
 4. Slide clutch housing (item #14) from end of
drum shaft. Remove setscrew, spring and
poppet ball (items #42, #70 & #27) from jaw
clutch (item #6). Slide jaw clutch from end of
drum shaft. Remove ( 2) keys ( item #53 ) from
keyways. A screwdriver can be used, at notch,
to aid in removal of keys. Once keys have been
removed, drum (item #9) and thrust washer (item
#74) can be removed from drum shaft. Parts
under drum, thrust washer (item #73), spring
and disc (items #71&#48) should also be removed.

5. Remove bearing cap (item #5) from gear

housing by unscrewing four capscrews (item
#33).
Remove worm (item #25) and bearing (item
#29) 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 #25) and
bearings (item #29). Replace if necessary.
For models with optional worm brake refer to
page 5, SERVICING OF THE OIL COOLED
SAFETY BRAKE, for disassembly and page 6,
for re-assembly.

6. Remove gear housing cover (item #7) from

gear housing (item #16) by unscrewing five
remaining capscrews (items #33). Place cap
screw into two tapped holes of cover and
tighten. This will pull the cover loose from gear
housing. Remove cover gasket (item #51) and
pull shaft (item #24), with gear attached, and
spacer(item #74) from gear housing.

11
7. Check for signs of wear on gear teeth. If
replacement of gear is necessary, replace as
follows:
a) Press gear (item #13) from shaft
(item #24).
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 #54) into keyways. Press gear
(item #13) over shaft and keys. Gear
must be centered over keys.

8. Remove seal (item #67) from back of gear

housing (item #16). Check bushing (item
#31) for signs of wear. Press bushing
(item #31) from gear housing and replace
if necessary. Press new bushing and seal
back into place.

9. Check drum bushings (item #30) for signs of

wear. Replace if necessary by pressing old
bushings from drum and pressing new ones
into place.

10. Check clutch housing bushing (item #30)

for signs of wear. If necessary, remove old
bushings and press new bushings into
place. Apply grease to lube fittings (item #
55) to lubricate clutch shifter shaft.

12
 11. Check cover bushing (item #30) 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 motor (item
#57).

13. Check gears of spur gear shaft assembly for signs

of wear, replace if necessary. Press old gears
from shaft (item #22). Tap key (item #20) into
keyway of shaft (item #22). Press shaft through
gears so that gears are centered on shaft and key.

RE-ASSEMBLY
14. Apply grease to end of shaft, opposite gear. Apply
grease to bushing in gear housing (Item#16). Place
greased end of shaft through spacer (item #74) and
bushing in gear housing (item #16). Place gasket
(item #51) onto gear housing cover (item #7). Apply
grease to gear end of shaft and bushing in cover.
Place cover onto shaft and secure to housing with
five (item #33) capscrews at five lower holes.

13
15. Place winch, with gear housing cover down, on work
bench. Drum shaft should be in vertical position.
Slide thrust washer (item #73) over drum shaft and
slide downwards until washer rests on gear housing.
Set springs (item #71) and drag brake disc (item
#48) into pockets of gear housing. Grease bushings
in drum (item #9). Slide drum assembly onto drum
shaft with drum jaws upward.

16. Slide thrust washer (item #74) over end of drum

shaft. Press drum downward to compress drag
brake springs in gear housing. Insert keys (item
#53) 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 #6) over end of shaft
and slide jaw clutch over keys. NOTE: Be sure
that tapped hole on side of jaw clutch is on same
side of shaft as the two ball detents. Insert ball
poppet (item #27), spring (item #70) and setscrew
(item #42) into tapped hole of jaw clutch. If jaw
clutch and, or drum shaft have been replaced
two detents for ball MUST be drilled as follows:
Slide jaw clutch over end of shaft. Align jaws of
clutch with jaws of drum. Use a 1/4" dia. drill,
using hole in jaw clutch as a guide, to drill a 1/8"
deep detent in shaft. Slide jaw clutch upward 3/4"
and drill 2nd detent.
Apply grease to bushing in clutch housing assembly
(item #14). Set clutch housing onto end of drum
shaft. Pull jaw clutch upward, toward clutch
housing, enough to allow yoke in clutch housing,
to fit properly in groove around jaw clutch. Slide
clutch housing assembly and jaw clutch downward
into place. The setscrew should be tightened
enough to allow ball, when placed in ball detents, to
sufficiently lock jaw clutch "IN" and "OUT".

14
17. Press bearing (item #29) onto worm (item #25).
NOTE: Be sure thick shoulder of bearings
outer race (side with manufacturer's name and
number) is out, away from worm threads. Press
bearing and worm into gear housing. Slip
gasket (item #49) onto bearing cap (item #5).
Use four capscrews (item #33) to secure cap to
gear housing. Torque capscrews to 7 ft-lbs. (9.4
Nm) each. Attach solenoid assembly (item #1)
to gear housing. Use two (item #38) capscrews
and three (item #46) capscrews with three
flatwashers (item #34). Tighten capscrews to 7
ft-lbs. (9.4 Nm) each. Insert plug (item #62) into
tapped hole of cover. Permatex may be applied
to threads to help prevent oil leakage.
TIGHTEN plug securely.

18. Press bearing (item #29) 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 #49) onto
spur gear housing (item #15). Secure
spur gear housing to worm gear
housing using four capscrews (item
#37). Torque capscrews to 7 ft-lbs. (9.4
Nm) each.

Mount motor (item #57) to spur gear

housing (item #15) using three
lockwashers and nuts (items #47 & #45).
Attach solenoid cables to motor
terminals. Tighten all nuts securely.

15
19. Place snap ring (item #69) over end of worm shaft
(item #25) and set into snap ring groove. Insert key
(item #18) into keyway of worm shaft. Place
thrust washer (item #72) over each end of spur
gear shaft (item #22). Set spur gear shaft
assembly into bearing of spur gear housing. Slide
gear (item #11) and (item #72) thrust washer over
end of worm shaft (item #25). Insert pins (item
#63) into cover (item #8 ). Place gasket (item
#50) onto cover. Attach cover and gasket to spur
gear housing using twelve capscrews (item #32).

Torque capscrews to 8 ft. lb. (10.8 Nm.) each.

Insert plug (item #60) into bottom of spur gear
housing. Permatex may be applied to threads to
help prevent oil leakage.

Remove reducer and fitting (items #56 & #59) from

top of spur gear housing. Pour 1/2 pint 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 #3 & #4)

using six capscrews (item #36) with lock-
washers and capscrews (items #39 &
#35). Torque capscrews to 34 ft. lb. (46
Nm.) each. Insert plug (item #60) into
bottom of gear housing. Permatex may
be applied to threads to help prevent
leakage.

Pour 3/4 pint of EP 140 gear oil into

housing through hole in top of housing.

Insert relief fitting (item #56) into reduc-

er (item #59) . Reducer should then be
placed into hole on top of gear housing.
Tighten fitting and reducer securely.

16
 A B C D
WINCH
INCHES INCHES INCHES INCHES
MODEL
MM MM MM MM

7.78 11.31 8.94 13.12

DC-200
197,6 287,3 227,0 333,3

DCY-200 5.28 6.31 11.44 8.12

CONNECT POWER CABLE
134,1 160,3 290,5 206,3 FROM POSITIVE (+)
BATTERY TERMINAL HERE

6.22
157,9
2.12
53,9
6.75 2.50
A 171,4 63,5

B
4.56
2.25 115,8 .25
57,1 6,4

17
2.50
63,5
3.62 1.12
92,0 28,6

3.50
DIA.
88,9 6.41
DC-200 SERIES

162,8
7.25 DIA.
184,2
.69
17,5
DIMENSIONAL DRAWING

1.37
34,9
7.03 3.47
2.50 2.50 178,6 88,2
C 63,5 D 63,5
36.00
CONNECT GROUND CABLE
914,4
FROM MOTOR ISOLATED
GROUND TERMINAL TO
NEGATIVE
BATTERY TERMINAL.

DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS

18
DC-200 SERIES
EXPLODED VIEW

SEE PAGE 20 FOR

COMPONENT BREAKDOWN

SEE PAGE 19 FOR OPTIONAL WORM BRAKE PARTS LIST

 ITEM NO QTY PART NO DESCRIPTION ITEM NO QTY PART NO DESCRIPTION
1 1 271027 SOLENOID ASSEMBLY -12V 40 NOT USED
1 278028 SOLENOID ASSEMBLY - 24 V 41 1 416059 SETSCREW 3/8-16NC X 1/2 LQ. SOC. HD
2 1 282001 SWITCH ASSEMBLY 42 1 416040 SETSCREW 5/16-18NC X 1/4 LG. SQ. HD
3 1 302808 ANGLE (STD) 43 1 416084 SETSCREW 1/4 20NC X 1/2 SQ. HD.
1 302811 ANGLE (MOD. Y) 44 1 416109 SETSCREW 5/16-18NC X 1/2 LG. SQ. HD
4 1 302809 ANGLE (STD) 45 3 418040 NUT 3/8 - 24NF HX. REG Z/P
1 302810 ANGLE (MOD. Y) 46 3 418154 WASHER 1/4 FLAT ALUM.
5 1 316083 CAP-BEARING 47 10 418177 LOCKWASHER-3/8 MEO.SECT.Z/P
6 1 324161 JAW CLUTCH 48 2 330010 DRAG BRAKE
7 1 328134 COVER WORM GEAR HSG 49 2 442184 GASKET
8 1 328106 COVER SPUR GEAR HSG 50 1 442185 GASKET
9 1 332007 DRUM MOD. Y 51 1 442200 GASKET
1 332105 DRUM STD 52 NOT USED
10 1 334001 IDLER GGEAR 53 2 450006 KEY BARTH
11 2 334003 GEAR 54 4 450016 KEY BARTH
12 NOT USED 55 2 456006 LUB FITTING
13 1 334161 GEAR R.H. -60:1 56 2 456008 RELIEF FITTING
1 334163 GEAR R.H. -46:1 57 1 262037 MOTOR 12 V
14 1 338003 HOUSING-CLUTCH 1 262036 MOTOR 24 V
15 1 338203 HOUSING-SPUR GEAR 58 NOT USED
16 1 338273 HOUSING-GEAR 59 2 468002 REDUCER
17 NOT USED 60 2 468011 PIPE PLUG SQ.HO.

19
18 1 342023 KEY-SQUARE 61 2 468017 PLUG 114-18NPT SOC.HD.
19 1 342024 KEY-SQUARE 62 1 468018 PIPE PLUG SOC.HO.
20 1 342033 KEY-ROUND 63 2 470001 PIN
21 1 344008 LEVER 64 1 472013 PLUG PLASTIC
PARTS LIST

22 1 356901 SHAFT-SPUR 65 1 482013 RUBBER BOOT

23 1 356902 SHAFT-SHIFTER 66 1 486009 OIL SEAL
24 1 351479 SHAFT-DRUM STD 67 1 486017 OIL SEAL
1 357481 SHAFT DRUM MOD Y 68 1 486023 OIL SEAL
25 1 368001 WORM R.H. -60:1 69 1 490003 SNAP RING
1 368019 WORM R.H.-46:1 70 1 494001 SPRING POPPET
26 1 370055 YOKE 71 2 494002 SPRING POPPET
27 1 400001 BALL-POPPET 72 3 518002 THRUST WASHER
28 3 402001 BEARING-NEEDLE 73 1 518014 THRUST WASHER
Model DC-200 LEVER EQUIPPED

29 2 402002 BEARING-BALL 74 2 518015 THRUST WASHER

30 4 412003 BUSHING 75 NOT USED
31 1 412045 BUSHING
32 12 414038 CAPSCREW I/4-20NCx314 LG. HX.HD. Z/P GR.S FOR GASKET & SEAL KIT ORDER
33 9 414045 CAPSCREW I/4-20NCx718 LG. HX.HD. Z/P GR.S PART NO. 246039
34 3 414059 CAPSCREW I/4-20NCxl LG. HX.HO. Z/P
35 1 414279 CAPSCREW 3/8-16NCx3/4 LG. HX.HO. GR.S
36 6 414282 CAPSCREW 3/8-16NCxl-l/4 LG. HX.HD. Z/P
37 4 414845 GR.S CAPSCREW l/4-20NCxl LG. SOC.HO. NYLOK
38 2 414856 CAPSCREW I/4-20NCx3/4 LQ. SOC.HO.Z/P
39 1 414912 CAPSCREW 3/8-16NCxS/8 LQ. SOC.HO.
 DC-200 BRAKE
EXPLODED DRAWING
Item No Qty Part No. Description
101 1 306034 SPRING-FLAT
102 1 314008 CAM PLATE
103 1 328128 COVER
104 1 338007 HOUSING-BRAKE
105 1 340002 HUB
106 1 342027 KEY
107 1 352022 RETAINER PLATE
108 1 368021 WORM-R.H. 60:1 RATIO
109 1 368022 WORMrR.H. 46:1 RATIO
110 2 400003 BALL
111 2 414021 CAPSCREW 1/4-20NCx 1 LG. HX.HD. GR.5 NY-LOK HVY.PATCH
112 4 414039 CAPSCREW 1/4 20NCx 1 LG. HX.HD. GR.5
113 1 414228 CAPSCREW 3/8-16NCx-1/2 LG. HX.HD. ALL-THRD.
114 4 414821 CAPSCREW 1/4-20NCx7/8LG. BUTTON HD.
115 1 418036 NUT 3/8-ISNC HX.JAM
116 6 418154 WASHER-FLAT l/4 ALUM.
117 1 442189 GASKET
118 1 474001 PLATE-THRUST
119 1 486069 THREAD SEAL
120 1 494007 SPRING

20
 SOLENOID ASSEMBLY

278027 - 12V
278028 - 24V

ITEM NO. QTY. PART NO. DESCRIPTION

1 1 280009 CABLE&BOLT ASSY-W/ALL 12&24V SOLE
2 1 289077 WIRE ASSY-4.5LG,#6GA GPT BLK,2-TERM
3 1 289091 WIRE ASSY-EXT,FEM CONN TO SOL,PLA
4 1 328104 COVER-SOLEN,DC7&8,INJ/MOLD,PURC
5 2 364001 STRAP-COPPER,MAKE FROM FINISHED
6 2 364002 STRAP-COPPER ,MAKE FROM FINISHED
7 1 408038 BRACKET-SOL MTG,DC7,8,FOLDED,16G
8 2 416199 MACHSCREW8-32NCX1/2LG.RD HD SLO
9 4 416216 SCREW-#10-24NCX1/2LG,RDHD,SLOT,Z/
10 2 418004 NUT-HEX #10-24NC REG.,ZINC PLATED
11 2 418022 NUT-5/16-18NC HEX REG,ZINC PLATED
12 2 418140 WASHER-#10 FLAT STEEL,SAE,ZINC PLT
13 2 418142 WASHER-#8,FLAT,ALUMINUM
14 1 418163 LOCKWASHER-5/16 MED SECT,ZINC PLA
15 1 418164 WASHER-5/16 SHAKE PRF,INT TEETH,Z/P
16 1 418165 WASHER-5/16 SHAKE PRF,EXT TEETH,Z
17 1 430013 CONNECTOR-FEMALE RECEPTACLE,MO
18 1 440114 SOLENOID - 24 VOLT
18 1 440110 SOLENOID 12 VOLT
19 2 440071 TERMINAL TAB-MALE,AMP#61499-1,BRAS
20 1 482029 COVER-FEMALE RECEPTACLE,URETHA

21
 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. Attach the other motor field terminal (F-1)to one of the side terminals of the solenoid.
4. Ground the solenoid to the motor with a wire as shown.
5. Attach positive (+) battery wire to the opposite side terminal of solenoid. Ground the
negative (-) battery wire to the motor isolated ground terminal.
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. (See motor test procedure page 23).
8. To test the upper contacts use the same hookup except use the top terminals. (See Figure
2). When hooked up as shown in 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; ie: 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.
(TOP TERMINALS) (TOP TERMINALS)

SIDE SIDE SIDE SIDE

(SMALL) (SMALL)

SOLENOID SOLENOID

GROUND WIRE(-) FROM GROUND WIRE(-) FROM

SOLENOID TO MOTOR SOLENOID TO MOTOR

BATTERY BATTERY
MOTOR MOTOR
F2

F2
F1

F1
A

A
ISOLATED GROUND ISOLATED GROUND
TERMINAL TERMINAL

FIGURE-1 FIGURE-2

22
 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. Attach a wire (at least a number 6 wire) from positive (+) battery terminal to F-2 motor terminal.
Ground negative (-) battery terminal to motor isolated ground terminal. (See Figure 1). Motor
should now run.

To reverse the direction of rotation:

1. Attach jumper wire from F-2 to motor terminals. (See Figure 2).
2. Attach wire from positive (+) battery terminal to F-1 motor terminal.
Ground negative(-) battery terminal to motor isolated ground terminal. (See Figure 2).

NOTE: Always attach battery wire solidly to motor terminals. Make and break the connection of
negative (-) battery terminal at the motor isolated ground terminal. 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 draw should be ap-
proximately 65 to 70 amps. If after following the procedure outlined, and the test on the winch sig-
nificantly exceeds 70 amperes, refer to your Owner’s Manual for trouble shooting suggestions on the
mechanical portion of the winch. See Figure 3 for the solenoids connection to the motor and the
battery.
CW

F2 BATTERY
F2

F1

F1

A ISOLATED GROUND
TERMINAL
ISOLATED
GROUND SOLENOIDS TO MOTOR CONNECTIONS
BATTERY
FIGURE-1 THE DASHED LINES ARE CURRENT'S PATH IN FORWARD ROTATION.
SOLID LINES ARE CURRENT'S PATH AT ALL TIMES.
NOTE: DIRECTION OF MOTOR ROTATION DEPENDS ON WHICH SMALL
MOTOR-CLOCKWISE ROTATION TERMINAL OF EITHER SOLENOID IS CONNECTED TO BATTERY'S
POSITVE TERMINAL.

CCW

BATTERY
F2
F2

F1

F1
ISOLATED GROUND
A TERMINAL

ISOLATED SOLENOIDS TO MOTOR CONNECTIONS

GROUND THE DASHED LINES ARE CURRENT'S PATH IN REVERSE
BATTERY ROTATION. SOLID LINES ARE CURRENT'S PATH AT ALL TIMES.
FIGURE-2
MOTOR-COUNTER CLOCKWISE ROTATION FIGURE-3

23
 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.

This warranty does not obligate RAMSEY WINCH to bear the cost of labor or transportation
charges in connection with the replacement or repair of defective parts, nor shall it apply to a
product upon which repair or alterations have been made, unless authorized by Manufacturer, or
for equipment misused, neglected or which has not been installed correctly.

RAMSEY WINCH shall in no event be liable for special or consequential damages. RAMSEY
WINCH makes no warranty in respect to accessories such as being subject to the warranties of
their respective manufacturers.

RAMSEY WINCH, whose policy is one of continuous improvement, reserves the right to
improve its products through changes in design or materials as it may deem desirable without
being obligated to incorporate such changes in products of prior manufacture.

If field service at the request of the Buyer is rendered and the fault is found not to be with
RAMSEY WINCH’s product, the Buyer shall pay the time and expense to the field
representative. Bills for service, labor or other expenses that have been incurred by the Buyer
without approval or authorization by RAMSEY WINCH will not be accepted.

RAMSEY WINCH COMPANY

Post Office Box 581510 Tulsa, Oklahoma 74158-1510
Telephone: (918) 438-2760 FAX: (918) 438-6688

OM-912407-1013-Y
24