operating, service and maintenance manual model … · see asme b30.5 for general maintenance...

OPERATING, SERVICE ANDMAINTENANCE MANUAL

MODEL SCH 2900MODEL SCH 3600MODEL SCH 4900

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!

TABLE OF CONTENTS

INTRODUCTIONS ...............................................................................................................................1

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

SPECIFICATIONS ...............................................................................................................................1

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

WINCH MOUNTING ............................................................................................................................2

HYDRAULIC SYSTEM REQUIREMENTS ..............................................................................................2

PERFORMANCE CHARTS ...................................................................................................................3

OPERATIONS .....................................................................................................................................4

MAINTENANCE ..................................................................................................................................4

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

TROUBLE SHOOTING GUIDE ..............................................................................................................5

DIMENSIONAL DRAWINGS ................................................................................................................6

PARTS LIST AND PARTS DRAWINGS ............................................................................................ 8-9

LIMITED WARRANTY ......................................................................................................BACK COVER

PLEASE READ THIS MANUAL CAREFULLYThis manual contains useful ideas for obtaining the most efficient operation from your Ramsey Winch, and safety procedures one needs to know before operating a Ramsey Winch. Do not operate this winch until you have carefully read and understand the “WARNING” and “OPERATION” sections of this manual.

WARRANTY INFORMATIONRamsey Winches are designed and built to exacting specifications. Great care and skill go into every winch we make. If the need should arise, warranty procedure is outlined on the back of your self-addressed postage paid war-ranty 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*

NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.

SCH 2900Rated Line Pull (lbs) 2,900

(kg) 1,310

Gear Reduction .................................................................... 5.1:1

Weight (without cable) ........................................ 139 lbs. (54 kg)

LAYER OF CABLE 1 2 3 4 5

Rated Line Pull per Layer lbs 2900 2600 2400 2200 2100

kg 1310 1170 1080 990 950

Line Speed at 8 GPM fpm 59 63 68 73 78

mpm 17.9 19.1 20.6 22.1 23.7

Cable Capacity ft 30 65 100 140 185

m 9 19 30 42 56

* These specifications are based on recommended 5/16 in. (8 mm) EIPS wire rope.


(kg) ........................................................ 1,630

Gear Reduction .................................................................... 5.1:1


LAYER OF CABLE 1 2 3 4

Rated Line Pull per Layer

lbs 3600 3200 2900 2700

kg 1630 1450 1310 1220

Line Speed at 13 GPM

fpm 48 52 56 60

mpm 14 15.8 17 18.2

Cable Capacity ft 25 55 85 120

m 7 16 25 36

* These specifications are based on recommended 3/8 in. (9.5 mm) EIPS wire rope.

1


(kg) ........................................................ 2,220

Gear Reduction .................................................................... 5.1:1


LAYER OF CABLE 1 2 3 4

Rated Line Pull per Layer

lbs 4900 4400 4000 3600

kg 2220 1990 1810 1630

Line Speed at 8 GPM

fpm 51 55 59 64

mpm 15.5 16.7 17.9 19.5

Cable Capacity ft 25 55 85 120

m 7 16 25 36

* These specifications are based on recommended 3/8 in. (9.5 mm) EIPS wire rope.

NOTE: These service crane hoists meet or exceed all applicable ASME B30.5 standards.

WARNINGS:

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 WIRE ROPE AROUND DRUM BARREL IS REQUIRED TO HOLD THE LOAD.

WINCH MOUNTING

NOTE: Remove and discard the (4) 1/2” capscrews from the foot mounting holes in the end bearings. These capscrews hold on the foot mount spacers during shipping and should not be used for mounting.

It is most important that this winch be mounted securely so that the three major sections (the motor end, the cable drum, and the gear-housing end) are properly aligned. Excessive bushing wear is a symptom of misalignment.

When installed mid-mounted, at least one tie plate should be attached to the mounting feet at the bottom of the winch to maintain alignment. When installed foot-mounted, at least one tie plate should remain mounted at mid point of winch to maintain alignment. It is always preferable to use both tie plates in the installed configuration.

When mounting the winch, the mounting hole patterns described on page 6 should be used. The mounting surface must be flat within 0.015 inch and sufficiently stiff to resist flexing. If a steel plate is used for foot mounting it should be .750 inch thick. For this mounting application eight (8) 1/2-13NC x 2-1/4” Lg. Gr. 5 capscrews with lockwashers will be needed to mount winch. Note that the supplied foot-mount spacers (.88” thick) must be installed between the winch and the mounting plate. Capscrews should be torqued to 85 ft-lb. (115 Nm).

CAUTION: IF LONGER BOLTS ARE SUBSTITUTED TO MOUNT WINCH OR TO MOUNT A ROLLER GUIDE AT THE SIDE MOUNT PADS, GRADE 5 OR BETTER BOLTS SHOULD ALWAYS BE USED, AND BOLT LENGTH SHOULD BE SUCH THAT A MAXIMUM OF .56 INCH THREAD LENGTH ENGAGEMENT IS ACHIEVED IN THE TAPPED HOLES IN THE SIDES OF EACH END BEARING.

2

TYPICAL LAYOUT

3

PERFORMANCE CHARTS

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts below to properly match your hydraulic system to the winch performance. The charts consist of: (1) first layer line pull (LB) vs. working pressure (PSI) and (2) first layer line speed (FPM) vs. flow (GPM). A motor spool directional control valve is required.

PUMP

(.75 I.D. MINIMUM)LOW PRESSURE LINE(.50 I.D. MINIMUM)

HIGH PRESSURE LINE

SEE PERFORMANCERATED LOAD:PRESSURE ATMAX. FLOW &

(MOTOR SPOOL)4 WAY VALVE3 POSITION RELIEF

SYSTEM

PORTBRAKE

MOTOR

WITH BRAKE RELEASE SHUTTLEDUAL-A & B PORT CONTROL

CHARTS BELOW

60

50

40

20

30

LIN

E PU

LL-F

IRST

LAY

ER (L

B.)

LIN

E SP

EED

-FIR

ST L

AYER

(FPM

)

WORKING PRESSURE, PSI

00 600

1,000

2,000

1,8001,200 10

3,000

FLOW (GPM)50 10

SCH 2,900

100 5

FLOW (GPM)4,000

3,000

101,200

2,000

1,000

60000


LIN

E SP

EED

-FIR

ST L

AYER

(FPM

)

LIN

E PU

LL-F

IRST

LAY

ER (L

B.)

30

20

40

50

SCH 3,600

50

40

45

5,000

1,600 15100 5FLOW (GPM)

4,000

3,000

5800 1,200

2,000

1,000

40000


LIN

E SP

EED

-FIR

ST L

AYER

(FPM

)

LIN

E PU

LL-F

IRST

LAY

ER (L

B.)

15

10

35

20

25

30

SCH 4,900

2,100

OPERATION

The best way to get acquainted with how your winch operates is to make test runs before you actually use it. Plan your test in advance. Remember, you hear your winch, as well as see it operate. Get to recognize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Avoid conditions where load shifts or jerks occur, as they may indicate a dangerous situation.

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 load. After the job is done you can unspool and rewind for a neat lay of the cable.

MAINTENANCE

1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with broken strands, replace immediately.

2. Replace drum bushings and seals when seals begin to seep grease. Add additional lubricant, Mobilith SHC 007, to gears if required.

See ASME B30.5 for general maintenance procedures.

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. Place taped end of cable into narrow side of pocket on the cable drum. Wrap end of cable around cable anchor or puck and pull tight.

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.

4

CONDITIONS POSSIBLE CAUSE CORRECTION/ACTIONDRUM WILL NOT ROTATE AT NO LOAD

Brake damaged Inspect and replace brake

Gears damaged Inspect and replace damaged gears

Brake not releasing Brake damaged; inspect and replace.

DRUM WILL NOT ROTATE UNDER LOAD

Load greater than rated capacity of winch

Refer to Specifications page 1 for line pull rating

Low hydraulic system pressure Check pressure. Refer to Hydraulic Systems performance charts page 3

WINCH RUNS TOO SLOW Low hydraulic system flow rate Check flow rate. Refer to Typical Layout page 3

Motor worn out Replace motor

BRAKE WILL NOT RELEASE Brake damaged Inspect and replace

EXCESSIVE NOISE Hydraulic system flow too high Check flow rate. Refer to Typical Layout page 3

DRUM CHATTERS IN “REEL IN” DIRECTION

Low hydraulic system flow rate Check flow rate. Refer to Typical Layout page 3

Low hydraulic system relief pressure setting

Check relief valve setting.

OIL SEEPAGE FROM BREATHER VENT OF BRAKE HOUSING

Brake piston not sealing properly Replace o-ring and backup o-rings on brake piston

TROUBLESHOOTING GUIDE

5

SCH

290

0, 3

600,

& 4

900

6

DIM

ENSI

ON

SCH

-290

0SC

H-3

600

SCH

-490

0

A8.

34/2

11,7

8.46

/214

,89.

27/2

35,4

B12

.82/

325,

612

.94/

328.

613

.75/

349,

3

C20

.99/

533,

121

.11/

536,

121

.92/

556,

8

MO

TOR

CO

NTR

OL

VALV

E D

ETA

IL

WIN

CH

MO

UN

TIN

G C

AP

SC

RE

WS

MU

ST

ME

ET

OR

EX

CE

ED

SA

E G

RA

DE

5 S

PE

CIF

ICAT

ION

NO

TE: T

HE

SE

HO

LE L

OC

ATIO

NS

MU

ST

BE

HE

LD W

ITH

IN ±

.03"

(0,8

MM

) OF

TRU

E P

OS

ITIO

N. R

EC

OM

ME

ND

ED

MO

UN

TIN

G H

OLE

DIA

ME

TER

IS .5

3" (1

3,5

MM

).

*

(TY

P)

.88

22,3

FOO

T M

OU

NT

SPA

CE

RTH

ICK

NE

SS

6.20

157,

4

FLA

NG

E D

IA.

10.6

226

9,8

3.10

78,7

1.12

28,4

* (TY

P)

*4.

5011

4,3

*2.

2557

,2

10.8

127

4,5

5.50

139,

7

5.94

150,

8

11.8

630

1,2

C LD

RU

M 6.50

165,

1B

AR

RE

L D

IA.

*4.5

011

4,3

9.00

228,

6*

A5.

2513

3,3

B

C

1/2-

13U

NC

x .7

5"(1

9,1m

m) D

EE

PTA

PP

ED

HO

LE (4

-PLA

CE

S E

AC

HE

ND

BE

AR

ING

)

4.23

107,

4

A

A

DIM

EN

SIO

NS

SH

OW

N A

RE

INC

HE

S O

VE

R M

ILLI

ME

TER

S

O-RI

NG P

ORT

(TYP

. 2 P

LACE

S).8

75-1

4 SA

E ST

RAIG

HT T

HREA

D

WINCH

1.75 44,5

22,4

.88

ROTA

TION

VIE

WED

FRO

M M

OTOR

END

PRES

SURE

IN G

IVES

COU

NTER

-CLO

CKW

ISE

DRUM

PRES

SURE

IN G

IVES

CLO

CKW

ISE

DRUM

ROTA

TION

VIE

WED

FRO

M M

OTOR

END

C L

A-A

VIE

W

TULSA OK

RAMSEY WINCH CO

8

52

34 20

2025 31

27

28

49

152533

47

2816

6

48 39

30 4347

29

46

2

MO

DE

L S

CH

-290

0, 3

600,

& 4

900

WIT

H B

LOC

KE

D C

LUTC

H

4517

8

42

5174

42 38

17

40

35

377 12

3613

1

19

14

11

3244

RAMSEY WINCH CO

TULSA OK

18521

5041

26

23

2422

310

9

PART

S LI

ST

9

Item

Qua

ntity

Part

No.

Des

crip

tion

Item

Qua

ntity

Part

No.

Des

crip

tion

11

2341

89D

RUM

ASS

EMBL

Y28

243

2018

FITT

ING

21

3060

42PI

STO

N-B

RAK

E29

443

8022

DIS

C-BR

AKE

31

3150

04AN

CHO

R- C

ABLE

301

4422

20G

ASKE

T-BR

AKE

HSG

.4

133

8300

END

BR

G-M

OTO

R E

ND

311

4422

23G

ASKE

T-M

OTO

R F

LAN

GE

51

3383

01EN

D B

RG

-GEA

R H

SG.

321

4440

85G

EAR

-RIN

G,P

/M6

133

8302

HSG

-BR

AKE

331

4560

38FI

TTIN

G-V

ENT,

BREA

THER

74

3460

45PI

N-B

RAK

E34

145

8119

MO

TOR

-HYD

RAU

LIC

(SCH

-290

0)8

135

7513

SHAF

T- IN

PUT

4581

21M

OTO

R-H

YDR

AULI

C (S

CH-3

600)

92

3622

91SP

ACER

- FO

OT

MO

UNTI

NG

4581

24M

OTO

R-H

YDR

AULI

C (S

CH-4

900)

104

3622

84SP

ACER

- TI

E PL

ATE

351

4620

46O

-RIN

G11

140

2120

BEAR

ING

361

4620

56O

-RIN

G12

140

2121

BEAR

ING

371

4620

57O

-RIN

G13

141

2084

BUSH

ING

-DR

UM,M

OTO

R E

ND

381

4620

58O

-RIN

G14

141

2085

BUSH

ING

-DR

UM,G

EAR

EN

D39

146

2059

O-R

ING

-BAC

K-UP

154

4141

29CA

PSCR

EW 5

/16-

18N

CX3

LG H

X H

D G

R-5

401

4620

60O

-RIN

G-B

ACK-

UP16

641

4303

BOLT

-3/8

-16N

C X2

1/2

,HXH

D,G

R-5

, Z/P

411

4720

52PL

UG17

841

4548

CAPS

CREW

-1/2

-13N

CX1

1/2,

HXH

D,Z

/P,G

542

247

4065

TIE

PLAT

E18

241

4854

SCR

EW-1

/4-2

0NCX

1/2L

G,R

DH

D,S

LOT,

Z/PL

435

4741

11PL

ATE-

SEPA

RAT

OR

, BR

AKE

191

4149

26SE

TSCR

EW-3

/8-1

6NC

X1,S

OCK

ET,N

YLO

N44

148

6080

SEAL

202

4149

48CA

PSCR

EW-1

/2-1

3NCX

1 1/

4LG

,SO

CKET

HD

451

4900

37SN

AP R

ING

211

4160

16SE

TSCR

EW1/

4-20

NCX

1/4

HX

SOCK

HD

CUP

466

4941

10SP

RIN

G-B

RAK

E22

141

6080

SETS

CREW

-5/8

-18N

F X1

LG

,HXS

OCH

D,C

UP47

449

4112

SPR

ING

2 31

4180

36N

UT-3

/8-1

6 N

C,H

EX J

AM,Z

/P48

150

9009

TUBE

ASS

Y24

141

8088

NUT

-JAM

5/8

-18N

F H

EX H

D,Z

INC

PLT

491

5160

13VA

LVE-

MO

TOR

CO

NTR

OL

252

4182

18LO

CKW

ASH

ER-1

/2 ID

MED

SEC

T,ZI

NC

PLT

501

5180

37TH

RUS

T W

ASH

ER26

142

6048

PLUN

GER

-CLU

TCH

,BLO

CKED

511

5180

47TH

RUS

T W

ASH

ER27

143

1015

COUP

LIN

G-M

OTO

R52

151

8052

THR

UST

WAS

HER

LIMITED WARRANTY

RAMSEY WINCH warrants each new RAMSEY Winch to be free from defects in material and work-manship 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 work-manship.

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 respec-tive 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 ser-vice, labor or other expenses that have been incurred by the Buyer without approval or authorization by RAMSEY WINCH will not be accepted

See warranty card for details.

RAMSEY WINCH COMPANY

PO BOX 581510 Tulsa OK 74158-1510Telephone: (918) 438-2760 FAX: (918) 438-6688http://www.ramsey.com 914168-0816-E

operating, service and maintenance manual model … · see asme b30.5 for general maintenance...

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