Ramsey Winch Powermaster 15,000 Installation and user guide

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

4
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.
m
30
9
70
21
115
35
165
20
220
67
** Line Speed
(at 30 GPM)
FPM
MPM
53
(16.1)
60
(18.2)
67
(20.3)
75
(22.8)
82
(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:

5
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.

6
CONTROL VALVE
3 POSITION
4 WAY VALVE
(MOTOR SPOOL)
HIGH PRESSURE LINE
DUAL-A & B PORT CONTROL
WITH BRAKE RELEASE SHUTTLE
BRAKE
PORT
B
MOTOR
A
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
0
15000
LINE PULL (LBS) FIRST LAYER
WORKING PRESSURE (PSI)
500 1000 1500 2000 2500
6000
3000
9000
12000
FLOW (GPM)
40
30
30
10
20
252015105
LINE SPEED, FT/MIN, FIRST LAYER
50
0
0
60

7
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.

8
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
4.
-----------------------------------------------------------------------------------------------------------------------------------
BRAKE WLL NOT HOLD 1. Incorrect directional control 1. Use only a motor spool
(Cylinder spool, closed
center.)
(open center) directional
control center valve.

9
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.
74
55
55
21
28
28
28
28
22
27

10
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.
27
27
22
37
15
14
63
38
61
43
43
38
63
61
43
43

11
5. Remove (6) capscrews #30 and clutch housing cover #7. Remove relief fitting #44 and plug
#54 from clutch housing cover #7 as shown. Remove clutch housing o-ring #52 and plug #64.
Pull shifter lever away from drum and slide clutch yoke #20 from shaft.
7
54
30
44
52
20
64

12
6. Slide clutch end bearing #2 from drum. Drum freespool drag puck #12, drum freespool spring
# 68, and brake disc spacer # 73 will fall out when end bearing is removed from drum. Retain
these items for re-assembly.
To remove shifter yoke #19, drive spring pin #59 inward through shifter yoke. Lift shifter
assembly out by pulling up on shifter handle assembly #5 until shifter shaft #18 is clear of
shifter yoke #19. Yoke can then be lifted out of end bearing.
To replace handle #5 on shifter shaft #18, first remove spring pin #59, then slide handle
assembly #5 from shifter shaft #18. O-ring #53 can be replaced at this time.
To replace shifter detent bracket #23, first remove (2) ¼ x 20 capscrews #26 and (2) ¼
lockwashers # 35, then remove shifter detent bracket #23 and replace.
12
68
23
35
54
26
73
34
29
74
19
58
2
18
59
53
5

13
7. Remove drum bushing assembly #25. Note that the (6) spring pins #62 are pressed into the
bushing and cannot be removed. To replace the drum bushing, first press in the (6) spring pins
#62, and then replace the bushing on the shaft. Drum seal #65 can also be replaced at this
time if needed.
Note: Replacement bushings do not include the pins so you will need to order them
separately.
62
25
65

14
8. Remove output shaft #16, output carrier assembly #1, and input carrier assembly #6 from
drum #13. Disassemble in the following order:
Knock (3) spring pins #57 inward to center of input carrier assembly #6. Remove (3) input
planet pins #60 from input carrier assembly #6. Remove (3) input planet gears #4 from input
carrier assembly #6.
Remove output shaft external retaining ring #67 from output shaft #16. Slide input carrier #6
from output shaft #16.
Remove thrust washer #72 from output shaft #16. Slide output carrier assembly #1 from output
shaft #16. Output carrier assembly #1 must be purchased as an assembly. Replacement gears
are not available.
13
16
1
57
4
60
6
72
57
4
60 57
4
60
67

15
9. Remove drum #13 from motor end bearing #3. Remove drum seal #65. Check for signs of
wear and replace if necessary.
10.Remove input shaft #17 from motor end bearing #3.
3
13
65
17
3

16
11.To remove motor #45 from motor end bearing #3, first detach hydraulic brake release hose
assembly #70 from elbow fitting #40. Loosen (2) ½-13 capscrews #32. Remove motor gasket
#42, and (11) brake springs #69.
To remove motor control valve #71, loosen (3) 3/8-16 NC capscrews #31, lift motor control
valve #71 from motor #45.
Note: Do not run winch with hydraulic brake release hose assembly disconnected.
TORQUE CHART
SIZE TORQUE VALUE
1/4-20 76 IN LBS
3/4-16 223 FT LBS
3/8-16 23 FT LBS
1/2-13 57 FT LBS
SIZE TORQUE VALUE
1/2-13 80 FT LBS
5/8-11 159 FT LBS
GRADE 5
GRADE 8
70
41
70
3
32
45
71
69 42
31
40
TO ITEM 40
TO ITEM 41

17
12. Remove (2) retaining rings #66. Remove motor coupling #39 from end bearing #3. Remove roll
pin #56 from motor coupling #39. Remove brake piston #10 and backup brake piston #11.
Remove o-ring #47, o-ring #46, backup ring #49, and backup ring #51from brake piston #10.
Remove o-ring #48 and backup ring #50 from backup brake piston #11. Remove (7) stators #8
and (6) brake discs #9 from end bearing #3.
To re-install brake, set gear housing end down on work surface.
Install well-oiled o-rings and backup rings into grooves on outside of brake piston and backup
brake piston as shown in cross-section A-A below.
Piston, backup piston, brake discs and stators must be clean and well lubed with 80W-140 oil.
Insert (7) stators #8 and (6) brake discs #9 into gear end alternating, with stators first and last.
Insert backup brake piston #11 on to brake piston #10. Insert brake piston assembly into motor
end bearing #3. Apply even pressure on piston when installing.
Insert roll pin #56 into motor coupling #39 below bottom of spline teeth. Insert motor coupling
#39 into end bearing #3.
Install (2) retaining rings #66 into grooves in motor end housing.
11 10
MOTOR SIDEDRUM SIDE
SECTION A-A
A
A
910
11
8
3
41
47
49
39
66
56
50
48
51
46
51 46
50
48
47
49

18
3.18
(PORT)
11.00
6.63
3.94
(TOP OF BOTTOM ROLLER)
7.50
15.99
12.40 (PORT LOCATION)
Ø 1.00
(ROLLER OPENING)
27.09
1.06
2.13
9.50
5.50
5.38
1.13
2.13
1.06
6.82
13.63 19.00
1.062-12 SAE STRAIGHT THREAD O-RING PORT (2-PLACES)
OIL LEVEL PLUG
1/2-13 X 1.00 DEEP
TAPPED HOLES
(6-PLACES EACH SIDE OF WINCH)
Ø 6.75
BARREL
Ø 13.25
FLANGE
Ø 1.50
(TYP)
8.19
Ø 1.50
(TYP)
10.28
OIL FILL PLUG (16 OZ 75W-90 SYNTHETIC GEAR OIL)
Ø.625
CABLE
ANCHOR
OIL FILL PLUG (16 OZ 75W-90 SYNTHETIC GEAR OIL)
DRIVE EXPANSION PLUG
472083 .062 BELOW FLUSH
18.06
6.71
13.46
10.63
DRUM FREE SPOOL
ADJUSTMENT BOLT
BREATHER
1/4" QUICK DISCONNECT AIR PORT.
VERIFY CORRECT ALIGNMENT BETWEEN COVER AND QUICK DISCONNECT.
90-110 PSI TO DISENGAGE.
*
*
15K DIMENSIONAL DRAWING (AIR SHIFT)

19
20K Dimensional Drawing
10.99
27.46
Ø1.00
(ROLLER OPENING)
2.12
5.491.06
19.00
9.49
6.63
3.08
(PORT)
3.94
(TOP OF BOTTOM ROLLER)
12.75 (PORT LOCATION)
16.36
5.38
1.13
2.13
1.06
6.82
13.63
7.50
Ø13.25
FLANGE
Ø1.50 (TYP)
Ø1.50
(TYP)
10.28
8.19
Ø6.75
BARREL
10.69
6.75
18.13
6.75
13.50
DRUM FREE SPOOL
ADJUSTMENT BOLT 1/2-13 X 1.00 DEEP
TAPPED HOLES
(4-PLACES EACH SIDE OF WINCH)
1.062-12 SAE STRAIGHT
THREAD O'RING PORT
(2-PLACES)
OIL FILL PLUG
(16 OZ. 80W-140 GEAR OIL)
OIL FILL PLUG
(16 OZ. 80W-140 GEAR OIL)
Ø.625
CABLE
ANCHOR
ENGAGED POSITION
DISENGAGED POSITION
(SHOWN)
OIL LEVEL PLUG
VENT
DRUM C
L
15K DIMENSIONAL DRAWING
(MANUAL SHIFT)

20
16
20K WINCH PARTS DRAWING
31
40
71
51 46 47
49
39 66
32
45
42
69
56
10
48
11
62
25
65
2
12
68
73
74
58
19
74 59
18
53
5
23
20
52
7
64
30
44
35
26
29
34
54
8
50
9
41
3
65
17
33
55
54
55
13
6
67
60
57
4
60
57
4
60
57
4
72
1
16
70
28
28
21
22
15
14
43
43
37
38
63
43 61
27
28
61
43
63
38
28
27
15