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SCH-4900
User Manual
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Ramsey SCH-4900 User Manual

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Page 1
OPERATING, SERVICE AND
MAINTENANCE MANUAL
MODEL SCH 2900 MODEL SCH 3600 MODEL SCH 4900
PLANETARY WINCHES
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!
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TABLE OF CONTENTS
INTRODUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HYDRAULIC SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PARTS LIST AND PARTS DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BACK COVER
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PLEASE READ THIS MANUAL CAREFULLY
This 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 INFORMATION
Ramsey Winches are designed and built to exacting specifications. Great care and skill go into every winch we make. If the need should arise, warranty procedure is outlined on the back of your self-addressed postage paid war­ranty card. 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 2900
Rated Line Pull (lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,900
(kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,310
Gear Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1:1
Weight (without cable) . . . . . . . . . . . . . . . . . . . .118 lbs. (54 kg)
LAYER OF CABLE 1 2 3
Rated Line Pull per Layer lbs 2900 2600 2400
kg 1310 1170 1080
Line Speed at 8 GPM fpm 59 63 68
mpm 17.9 19.1 20.6
Cable Capacity ft 30 65 100
m 9 19 30
* These specifications are based on recommended 5/16 in. (8 mm) EIPS wire rope.
SCH 3600
Rated Line Pull (lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,600
(kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,630
Gear Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1:1
Weight (without cable) . . . . . . . . . . . . . . . . . . . .120 lbs. (55 kg)
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 8 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.
SCH 4900
Rated Line Pull (lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,900
(kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,220
Gear Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1:1
Weight (without cable) . . . . . . . . . . . . . . . . . . . .125 lbs. (57 kg)
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.
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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: The winch must be mounted so that the cable reels in in the required direction as noted on page 6.
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.
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TYPICAL LAYOUT
PUMP
(.75 I.D. MINIMUM)
LOW PRESSURE LINE
(.50 I.D. MINIMUM)
HIGH PRESSURE LINE
SEE PERFORMANCE
RATED LOAD:
PRESSURE AT
MAX. FLOW &
(MOTOR SPOOL)
4 WAY VALVE
3 POSITION
RELIEF
SYSTEM
PORT
BRAKE
MOTOR
WITH BRAKE RELEASE SHUTTLE
DUAL-A & B PORT CONTROL
CHARTS BELOW
60
50
40
20
30
LINE PULL-FIRST LAYER (LB.)
LINE SPEED-FIRST LAYER (FPM)
WORKING PRESSURE, PSI
0
0
600
1,000
2,000
1,8001,200
10
3,000
FLOW (GPM)
5
0
10
SCH 2,900
10
0
5
FLOW (GPM)
4,000
3,000
10
1,200 1,800
2,000
1,000
600
0
0
WORKING PRESSURE, PSI
LINE SPEED-FIRST LAYER (FPM)
LINE PULL-FIRST LAYER (LB.)
30
20
40
50
SCH 3,600
50
40
45
5,000
1,600
15
10
0
5
FLOW (GPM)
4,000
3,000
5
800
1,200
2,000
1,000
400
0
0
WORKING PRESSURE, PSI
LINE SPEED-FIRST LAYER (FPM)
LINE PULL-FIRST LAYER (LB.)
15
10
35
20
25
30
SCH 4,900
9.6 cu.in. Motor 11.9 cu.in. Motor
18.7 cu.in. Motor
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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.
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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.
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.
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CONDITIONS POSSIBLE CAUSE CORRECTION/ACTION
DRUM 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
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PRESSURE IN GIVES CLOCKWISE DRUM
ROTATION VIEWED FROM MOTOR END
17,1
.675
PRESSURE IN GIVES COUNTER-CLOCKWISE DRUM
ROTATION VIEWED FROM MOTOR END
7/8-14 SAE STRAIGHT THREAD
O-RING PORT (2-PLACES)
19,8
.781
WINCH MOUNTING CAPSCREWS MUST MEET OR EXCEED SAE GRADE 5 SPECIFICATION
NOTE: THESE HOLE LOCATIONS MUST BE HELD WITHIN ±.03" (0,8 MM) OF
TRUE POSITION. RECOMMENDED MOUNTING HOLE DIAMETER IS .53" (13,5 MM).
REEL IN DIRECTION
4.50
114,3
9.00
228,6
5.25
133,3
B
C
1/2-13UNC x .75"(19,1mm) DEEP
TAPPED HOLE (4-PLACES EACH
END BEARING)
4.23
107,4
A
DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS
11.86
301,2
DRUM
6.50
165,1
BARREL DIA.
DIMENSION SCH-2900 SCH-3600 SCH-4900
A 8.34/211,7 8.46/214,8 9.27/235,4
B 12.82/325,6 12.94/328.6 13.75/349,3
C 20.99/533,1 21.11/536,1 21.92/556,8
A-A
MOTOR CONTROL VALVE DETAIL
WINCH
VIEW
(TYP)
.88
22,3
FOOT MOUNT SPACER
THICKNESS
6.20
157,4
FLANGE DIA.
10.62
269,8
3.10
78,7
1.12
28,4
(TYP)
4.50
114,3
2.25
57,2
10.81
274,5
5.50
139,7
5.94
150,8
SCH 2900, 3600, & 4900
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NOTES
Page 10
11
32
44
18
5
21
50
41
26
23
38
17
40
35
37
7
24
22
3
10
9
MODEL SCH-2900, 3600, & 4900
WITH BLOCKED CLUTCH
45
17
8
42
51
7
4
42
12
36
13
1
19
14
46
2
47
28
16
6
48
39
30
43
47
29
33
52
34
20
20
25
31
27
28
49
15
25
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Item Quantity Part No. Description Item Quantity Part No. Description
1 1 234189 DRUM ASSEM BLY 28 2 432018 FITTING
2 1 306042 PISTON-BRAKE 29 4 438022 DISC-BRAKE
3 1 315004 ANCHOR- CABLE 30 1 442220 GASKET-BRAKE HSG.
4 1 338300 END BRG-MOTOR END 31 1 442223 GASKET-MOTOR FLANGE
5 1 338301 END BRG-GEAR HSG. 32 1 444085 GEAR-RING
6 1 338302 HSG-BRAKE 33 1 456038 FITTING-VENT,BREATHER
7 4 346045 PIN-BRAKE 34 1 458119 MOTO R-HYDRAULIC (RPH-3600)
8 1 357513 SHAFT- INPUT 458121 MOTO R-HYDRAULIC (RPH-4900)
9 2 362291 SPACER - FOOT MOUNTING 458124 MOTO R-HYDRAULIC (RPH-2900)
10 4 362284 SPACER - TIE PLATE 35 1 462046 O-RING
11 1 402120 BEARING 36 1 462056 O-RING
12 1 402121 BEARING 37 1 462057 O-RING
13 1 412084 BUSHING-DRUM,MOTOR END 38 1 462058 O-RING
14 1 412085 BUSHING-DR UM,GEAR END 39 1 462059 O-RING-BACK-UP
15 4 414129 CAPSCREW 5/16-18NCX3 LG HX HD GR-5 40 1 462060 O-RING-BACK-UP
16 6 414303 BOLT-3/ 8-16N C X2 1/2,HXHD,GR-5, Z/P 41 1 472052 PLUG
17 8 414548 CAPSCREW-1/ 2-13N CX1 1/2,HXHD,Z/P,G5 42 2 474065 TIE PLATE
18 2 414854 SCREW-1/4-20N CX1/ 2LG,RDHD,SLOT,Z/PL 43 5 474111 PLATE-SEPARATOR, BRAKE
19 1 414926 SETSCREW-3/8-16NC X1,SOCKET,N YLON 44 1 486080 SEAL
20 2 414948 CAPSCREW-1/ 2-13N CX1 1/4LG,SOCKET HD 45 1 490037 SNAP RING
21 1 416016 SETSCREW1/4-20NCX1/4 HX SOCK HD CUP 46 6 494110 SPRING-BRAKE
22 1 416080 SETSCREW-5/8-18NF X1 LG,HXSOCHD,CUP 47 4 494112 SPRING
23 1 418036 NUT-3/8-16 NC,HEX JAM,Z/P 48 1 509009 TUBE ASSY
24 1 418088 NUT-JAM 5/8-18NF H EX HD,ZINC PLT 49 1 516033 VALVE-MO TOR CONTROL
25 2 418218 LOCKWASHER-1/2 ID MED SECT,ZINC PLT 50 1 518037 THRUST WASHER
26 1 426048 PLUNGER-CLUTCH,BLOCKED 51 1 518047 THRUST WASHER
27 1 431015 COUPLING-MO TOR 52 1 518052 THRUST WASHER
PARTS LIST
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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
See warranty card for details.
RAMSEY WINCH COMPANY
PO BOX 581510 Tulsa OK 74158-1510 Telephone: (918) 438-2760 FAX: (918) 438-6688 http://www.ramsey.com
914168-0207-C
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