Ramsey Winch Powermaster 15,000 Installations- und Benutzerhandbuch

OM 914272-1114-A

OPERATING, SERVICE

AND MAINTENANCE

MANUAL

15,000 LB INDUSTRIAL WINCH

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION

AND OPERATION OF WINCH. SEE WARNINGS!

TABLE OF CONTENTS

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

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

WARNINGS....................................................................................................................................................1

CABLE INSTALLATION ...................................................................................................................................2

HYDRAULIC SYSTEM REQUIREMENTS............................................................................................................3

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

CLUTCH OPERATION .....................................................................................................................................4

WINCH OPERATION .......................................................................................................................................4

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

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

INSTRUCTIONS FOR OVERHAUL.....................................................................................................................6

TORQUE CHART .........................................................................................................................................13

15K DIMENSIONAL DRAWING .....................................................................................................................15

15K WINCH PARTS DRAWING ......................................................................................................................16

PARTS LIST - 15K WINCH ...........................................................................................................................16

LIMITED WARRANTY ...................................................................................................................................21

RAMSEY HYDRAULIC PLANETARY WINCH MODEL 15K

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. Do not operate this winch

until you have carefully read and understand the “WARNINGS” 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*

CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.

DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH.

DO NOT DISENGAGE CLUTCH UNDER LOAD.

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 PEOPLE.

A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.

CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD.

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

Rated Line Pull (lbs.)

…………………………………………………………………………. 15,000

(Kg.) ………………………………..………………………………………..

(6800)

Gear Reduction …………………………………………..……………………………………… 21:1

Weight (without cable) 15K Winch………………………………….…………….…………. 337 lbs

LAYER OF CABLE 12345

*Rated line pull

per layer

lbs.

Kg.

15,000

6,800

13,000

5,890

11,400

5,170

10,200

4,620

9,200

4,170

* Cable Capacity per Layer

20K Winch ft.

115

165

220

** Line Speed

(at 30 GPM)

FPM

MPM

(16.1)

(18.2)

(20.3)

(22.8)

(24.9)

* Cable Capacity per layer

** These specifications are based on recommended wire rope of 9/16” (14 mm)

diameter EIPS cable and a 11.9 cu. in / Rev. motor.

WARNINGS:

29 34

SETSCREW

INSERT CABLE

BETWEEN HORIZONTAL

ROLLERS OF ROLLER

GUIDE AND INTO POCKET

ON DRUM AS SHOWN

SECURE WITH SETSCREW

CABLE INSTALLATION

1. Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of wire rope,

opposite hook, with plastic or similar tape to prevent fraying.

2. Place taped end of cable through roller guide and into hole in cable drum as shown below. Use

3/8”-16NC X 3/8” Lg. Hex socket drive setscrew to secure cable to drum.

3. Carefully run the 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.

After installing cable, check freespool operation. Disengage clutch and pull on cable at walking speed.

If cable “birdnests”, loosen jam nut #34 and turn 3/8”-16NC capscrew #29 clockwise to increase drag

on drum. If cable pull is excessive, loosen 3/8”-16NC capscrew #29 by turning counterclockwise.

Tighten jam nut when proper setting is obtained.

CONTROL VALVE

3 POSITION

4 WAY VALVE

(MOTOR SPOOL)

HIGH PRESSURE LINE

DUAL-A & B PORT CONTROL

WITH BRAKE RELEASE SHUTTLE

BRAKE

PORT

MOTOR

TYPICAL LAYOUT

LOW PRESSURE LINE

PUMP

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts, below, to properly match your hydraulic system to Linemaster 15K winch

performance. The charts consist of:

(1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) Line speed, first layer (FPM) vs. gallons per

minute (GPM). Performance based on a motor displacement of 11.9 cubic inches with 30 GPM maximum

flow rate. Motor has (2) 1.062-12 SAE straight thread o-ring ports.

Note: A motor spool (open center) directional control valve is required for brake operation.

PERFORMANCE CHARTS

BASED ON 11.9 CU IN/REV MOTOR

15000

LINE PULL (LBS) FIRST LAYER

WORKING PRESSURE (PSI)

500 1000 1500 2000 2500

6000

3000

9000

12000

FLOW (GPM)

252015105

LINE SPEED, FT/MIN, FIRST LAYER

CLUTCH OPERATION

WARNING: CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERATION.

To engage clutch:

1. Grasp shift lever and push toward drum to the “In” position.

2. If shift lever detent does not engage to the detent hole, then the clutch is not fully engaged. The cable

drum may need to be manually rotated slightly while pushing on the shift lever to align the clutch

splines.

WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD.

To disengage clutch:

1. Run the winch in the "cable out" direction until the load is off the cable.

2. Grasp the shift lever and pull away from drum to the “Out” position until shift lever detent engages in

detent hole. If there is resistance in moving the shift lever, the cable drum may be manually rotated in

the cable “Out” direction thereby relieving the preload and allowing the lever to shift. The cable may

now be pulled off by hand.

WINCH OPERATION

The best way to get acquainted with how your winch operates is to make test runs before you use it.

Plan your test in advance. Remember, you hear your winch, as well as see it operate; learn to recognize

the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Gain conﬁ-

dence 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.

MAINTENANCE

Adhering to the following maintenance schedule will keep your winch in top condition and performing as it

should with a minimum of repair.

A. WEEKLY

1. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and

repair.

2. Check the pressure relief plug on the gear housing cover. Be sure that it is not plugged. Lubricate

cable with light oil.

B. MONTHLY

1. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are

loose. Use grade 8 or better bolts.

2. 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 seconds 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 75W-90 synthetic gear oil.

4. Inspect bumper and surrounding structure for cracks or deformation.

TROUBLE SHOOTING GUIDE

-----------------------------------------------------------------------------------------------------------------------------------

CONDITIONS

POSSIBLE CAUSE

CORRECTION

-----------------------------------------------------------------------------------------------------------------------------------

OIL LEAKS FROM

WINCH 1. Seals damaged or worn. 1. Replace seal.

2. Too much oil. 2. Drain excess oil.

Refer to

OPERATION.

3. Damaged gaskets. 3. Replace gaskets.

4. Damaged o-rings. 4. Replace o-rings.

-----------------------------------------------------------------------------------------------------------------------------------

WINCH RUNS TOO SLOW

1. Low flow rate 1. Check flow rate. Refer

to HYDRAULIC

SYSTEMS

performance chart

page 3.

2. Hydraulic motor worn out. 2. Replace motor.

----------------------------------------------------------------------------------------------------------------------------------

CABLE DRUM WILL NOT

1. Clutch not disengaged 1. Check operation, refer to page

FREESPOOL

-----------------------------------------------------------------------------------------------------------------------------------

BRAKE WLL NOT HOLD

1. Incorrect directional control 1. Use only a motor spool

(Cylinder spool, closed

center.)

(open center) directional

control center valve.

INSTRUCTIONS FOR OVERHAUL

1. Drain oil from gear housing by removing plug #74 from drain hole in end bearing.

2. Freespool drum to locate drain hole in bottom. Remove plugs #55 from barrel of drum. Drain oil

from drum barrel. Remove tie plate #21 by loosening (2) capscrews #28 each side. Loosen but

do not remove (2) capscrews #27 on roller guide tie plate #22. Remove (4) capscrews #28 and

roller guide.

3. Position roller guide face down on a level surface and (2) capscrews #27 and roller guide tie

bar #22. Horizontal rollers #37 can be removed from the left and right hand roller guides once

the tie bar has been removed. Horizontal rollers #37 have (2) lube fittings #43, one located at

either end of the roller.

4. Remove vertical roller pin #61 from right hand side of roller guide #14 by removing spring pin

#63. Spring pins should be removed by driving inward through the roller. Vertical roller pin #61

has (2) lube fittings #43, one located at either end of the roller pin. Once the vertical roller pin

is removed from right hand side of roller guide, vertical roller #38 can be removed. Remove

vertical roller from left hand side of roller guide #15 in the same way.

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