OM-914273-0715-C

WILDCAT 65K MODEL WC 65R 65,000 LB INDUSTRIAL WINCH

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

OPERATING, SERVICE AND MAINTENANCE MANUAL

3

TABLE OF CONTENTS

WARRANTY INFORMATION …………………………………………………… 1

SPECIFICATIONS …………………………………………………… 1

WARNINGS …………………………………………………… 1

HYDRAULIC SYSTEM REQUIREMENTS …………………………………………………… 2

PERFORMANCE CHARTS …………………………………………………… 2

CABLE INSTALLATION …………………………………………………… 3

CLUTCH OPERATION …………………………………………………… 4

WINCH OPERATION …………………………………………………… 6

MAINTENANCE …………………………………………………… 6

LUBRICATION TABLE …………………………………………………… 7

TROUBLE SHOOTING GUIDE …………………………………………………… 7

INSTRUCTIONS FOR WINCH DISASSEMBLY …………………………………………………… 8-12

WILDCAT HOSE HOOKUP …………………………………………………… 14

PARTS DRAWING …………………………………………………… 16

PARTS LIST …………………………………………………… 17

AIR CYLINDER PARTS LIST …………………………………………………… 18

DIMENSIONAL DRAWING …………………………………………………… 19

LIMITED WARRANTY …………………………………………………… 20

1

PLEASE READ THIS MANUAL CAREFULLYThis 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 manu-al.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 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.

WARNINGS: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. BAND BRAKE IS NOT TO BE USED TO HOLD LOAD

RAMSEY HYDRAULIC PLANETARY WINCH MODEL WILDCAT 65K

APPROXIMATE WEIGHT: ……………………………………………………………………………………………………………… 1305 LBSWORKING PRESSURE: …………………………………………………………………………………………………………………. 2600 PSICABLE DIAMETER: ………………………………………………………………………………………………………………………. 1 INCHMAX FLOW: ………………………………………………………………………………………………………………………………. 60 GPM

LAYEROF

CABLE Ft m Lb Kg fpm mpm Lb Kg fpm mpm1 40 12 65000 29480 34 10 26500 12020 76 232 90 27 53100 24080 41 12 21600 9790 91 273 150 45 45000 20410 48 14 18300 8300 106 324 215 65 39000 17690 55 16 15900 7210 121 37

CABLE CAPACITY

LOW SPEED

* These speci ca ons are based on recommended wire rope of 1" Extra Improved Plow Steel Cable and a 10.9 cu. in. / Rev. motor.

HIGH SPEEDLINE PULL LINE SPEED LINE PULL LINE SPEED

2

Refer to the performance charts, below, to properly match your hydraulic system to winch perfor-mance. The charts consist of:(1) Line pull (lb.) fi rst layer vs. working pressure (PSI) and (2) line speed, fi rst layer (FPM) vs. gallons per minute (GPM). Performance based on a motor displacement of 10.9 cubic inches/rev with 60 GPM maximum fl ow rate. Motor has (2) 1”-12 SAE straight thread o-ring ports.

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

PORT#3

COUNTER BALANCE/SPEED SELECTOR BLOCK

BRAKE

DIRECT LINE TO TANK

PAYOUT

COUNTER BALANCEVALVE

RELIEF

4 WAY VALVE3 POSITION

SYSTEM

PUMP

CUSTOMERSUPPLIED

MOTOR CASE DRAIN

SAE -16

PORT #1PORT #5

PAYIN

MOTOR 2 SPEED

1" TUBING SIZE

1" TUBING SIZESAE -16

LOW PRESSURE LINE

HIGH PRESSURE LINE

12 VDC SHIFT SOLENOID

60K AIR CONNECTIONS

BAND BRAKECLUTCH

40

50

60

70

30

20

10

010 20 30 40 50 600

0 25002000150010005000

10000

20000

30000

40000

50000

80

90

3000

60000

65000

Line

Spe

ed (F

t/Min

)Fi

rst L

ayer

Flow (GPM)Working Pressure (PSI)

Line

Pul

l (Lb

s.)

Firs

t Lay

er

BASED ON 10.9 CU IN/REV MOTOR

HYDRAULIC SYSTEM REQUIREMENTS

PERFORMANCE CHARTS

3

CABLE INSTALLATION1. 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 around the drum and into the track on drum fl ange. Secure using supplied u-bolt #62 and (2) washers #64 and (2) nuts #65. 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.4. After installing cable, band brake is used to prevent bird nesting while pulling out cable, when clutch is disengaged.

62

64

65

INSERT CABLE AS SHOWN

CABLE INSTALLATION

4

CLUTCH OPERATION

WARNING: CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCHING OPERA-TION.To engage clutch: 1. Move clutch control to engage the clutch.2. Run the motor in the cable out direction until the drum begins to turn.

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. Move the clutch control to disengage the clutch. The cable may now be spooled off.

WINCH OPERATIONThe 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 rec-ognize 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.MAINTENANCEAdhering to the following maintenance schedule will keep your winch in top condition and performing as it should.

Drum bushings are oil impregnated with synthetic oil. The drum bushings do not require additional grease.

A. WEEKLY1. 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 and the brake housing cover. Be sure they are not plugged. 3. Lubricate cable with light oil.4. Apply a high quality lithium grease to clutch spline. Apply band brake to control drum. Declutch drum and apply grease to spline between clutch and drum. B. MONTHLY1. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are loose. Use grade 5 or better bolts.2. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.C. ANNUALLY1. Drain the oil from the winch annually or more often if winch is used frequently.2. Refi ll the winch to the oil level plug with all purpose GL-5 oil, (see page 6) or gear lube compat- ible with your climate.3. Inspect winch for damage and wear.

CLUTCH OPERATION

5

LUBRICATION TABLE

Min Ambient & Opera ng

Max Ambient

Max Opera ng

80W140 Synthe c -25 (-32) 125 (52) 225 (107)75W90 Synthe c -40 (-40) 115 (46) 215 (102)80W90 Conven onal -20 (-29) 100 (38) 180 (82)85W140 Conven onal 20 (6) 120 (50) 200 (93)

Lubricant Descrip on*

Temp Range F(C)

*Use API GL-5 or EP lubricants.

CONDITIONS POSSIBLE CAUSE CORRECTION

OIL LEAKS FROM WINCH 1. Seals damaged or worn.

2. Too much oil.

3. Damaged o-rings.

4. Case drain not connected.

1. Replace seal

2. Drain excess oil. Refer to page 7.

3. Replace o-rings.

4. Connect case drain.

WINCH RUNS TOO SLOW 1. Low flow rate.

2. Hydraulic motor worn out.

1. Check flow rate. Refer to Hydraulic Systems Performance Chart, page 3

2. Replace motor.

CABLE DRUM WILL NOT FREESPOOL

1. Clutch not disengaged 1. Check operation, refer to Clutch Operation, page 5.

BRAKE WLL NOT HOLD 1. Incorrect directional control valve (cylinder spool, closed center).

2. Excessive hydraulic system back pressure.

3. Sprag clutch worn out.

1. Use only a motor spool (open centerdirectional control valve.

2. Reduce system back pressure to lessthan 100 psi.

3. Replace sprag clutch mechanism.

BRAKE WILL NOT RELEASE 1. Brake line disconnected or blocked 1. Repair brake line.

WINCH WILL NOT OPERATE AT HIGH SPEED

1. Shift solenoid not working. 1. Verify shift spool is energized.

WINCH OPERATES ERRATICALLY ON INHAUL

1. Sprag hub is reversed. 1. Install sprag hub correctly.

TROUBLE SHOOTING GUIDE

LUBRICANT CHART andTROUBLE SHOOTING GUIDE

6

55

54

54

44

4. Remove (2) nuts #408b from air cylinder #408a. Air cylinder may now be removed. If needed, mounting bracket #401 may be removed by removing pin #404 from pin #405 and then slid ing pin out of mounting bracket. Brake band #5 may be expanded over drum fl ange to barrel for easiest removal.

NOTE: BRAKE BAND FITS OVER DRUM FLANGE

5

14

401

66

408b

408a

405

404

INSTRUCTIONS FOR DISASSEMBLY

1. Remove wire rope from drum.2. Drain oil from winch by removing (2) plugs #54, removing the lower plug fi rst. 3. When replacing lubricant, use 160 oz of applicable lube for your climate from table on page 6 adding 4 oz at #44 and the remaining at # 55.

7

5. Remove motor #45 from winch by fi rst disconnecting hydraulic lines (see page 21), sole noid wires, and then remove (4) bolts #37. O-ring #72 may now be removed. 6. Remove brake cover #42 by removing (4) bolts #66. The cover is spring loaded, use care when removing. Remove o-ring #46 then springs #61 may be removed; residual oil may be present in the brake housing. 7. Remove piston #11 including o-rings and backup rings #47, #48, #49, and #50 by using a momentary puff of compressed air into the brake port located on top of the end bearing. Capture the piston by placing a shop rag over the opening prior to using air.8. Remove the sprag brake hub assembly #40, (7) stator plates #12, (6) disc brakes #13, and the spacer #28. The sprag brake hub assembly #40 is not a serviceable part, if damaged a replacement assembly should be ordered.

4028

12

13

4847

1149

5061

4642

6672

45

37

63

8

9. Remove (8) cover bolts #36; cover #10, and o-ring #51.10. Remove snap ring #58, and sun gear #17.11. The planetary carrier assembly #4 may now be removed along with (2) spacers #24.12. Remove second snap ring #58 and intermediate sun gear #16.13. Planetary carrier assembly #3 may now be removed.

24

4

36

10

51

24

24

3

16

58

1758

9

14. Using a nylon strap, support ring gear #20 from a hoist or boom, this ring gear is heavy. Remove (8) bolts #37 leaving the top most bolt for last. Remove the fi nal bolt while support ing ring gear. Set ring gear aside. Remove the o-ring #52.15. Remove output sun gear #15. 16. Using a large pair of snap ring pliers remove the snap ring #60 from the shaft located inside the planetary carrier assembly #2. 17. Using a nylon strap and hoist slide the output planetary carrier #2 from the ring gear housing. The output planetary carrier is heavy.18. Remove the spacer #27.

52

20

37

15

60

227

10

19. Remove the clutch cylinder #1 by removing the (2) cotter keys #404 and (2) pins #406 from either end of the air cylinder #407.20. The clutch cylinder support angle #8 can be removed by removing the four bolts #38 and nuts #65 attaching it to the mounting angles.21. Remove the clutch yoke #29 by removing center pivot bolt #21 and nut #65.

8

29*

65

21

NOTE: VIEW SHOWN LESS DRUM AND ANGLE CUT AWAY FOR CLARITY

65

66

29*

1

66

* CLUTCH YOKE #29 SHOWN REMOVED AND PARTIALLY INSTALLED FOR CLARITY

402406

407

404

406

404

409

11

22. By removing snap ring #58 and ball bearing #31, the input shaft #22 may be removed. 23. To remove the motor end bearing #18, support drum #14 with a nylon strap or chain and hoist. Lift on the drum to tension the strap. Remove (6) bolts #67 and (6) nuts #68 attaching the end bearing to the mounting angles #6 and #7. The motor end bearing #18 will be sup ported on the output shaft end and may be slid off using a nylon strap and hoist to lift it.

67

68

18

22

3158

7

14

67

6

56

12

24. While continuing to support the drum #14, remove the clutch #9, snap ring #60 and spacer #25. 25. The output shaft #23 may be slid from the drum assembly. 26. The drum #14 is now supported only by the nylon strap and maybe removed as needed. 27. The (2) bushings #34 may be pressed from the drum if replacement is necessary.

14

34

23

25

60 9

34

13

28. To remove gear end bearing #18, from mounting angles #6 and #7, fi rst remove (4) 7/8-9NC bolts #67 and (4) nuts #68 from each angle. Shaft oil seal #56 and end bearing bushing #33 can be removed and replaced at this time, if necessary.

6719

33

56

67

7

6

68

68

14

71

41

53

71 41

32

69

41

59

71

30

32 70

39

HOSE HOOKUP

15

NOTES

16

4455 19

27

260

1552 20

373

16

458

1758 24 51

3654

10

5468

3356

5

67

6

3414

62

6465

3423

2560

922

21

5729

1

8

3518

766 67 37 37

63

45

44

6111 47

4813 12 28

58

31

40

495046426672

NOTE

S:

1. I

TEM

1 -

AIR

CYLI

NDER

KIT

CON

TAIN

S FA

STEN

ERS

AND

C

YLIN

DERS

FOR

CLU

TCH

AND

BAN

D BR

AKE.

2. I

TEM

63

CONT

AINS

FAS

TENE

RS F

OR B

RAKE

VAL

VE.

3. H

OSE

KIT

CONT

AINS

FIT

TING

S AN

D H

OSE.

6865

1

24

74

65

EXPLODED VIEW

17

ITE

M

QT

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ART

NO

DE

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RIP

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EM

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TY

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2561

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ER

38

NO

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SE

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125

1314

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TP

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CA

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IER

AS

SE

MB

LY39

143

2018

FIT

TIN

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IC O

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G E

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129

6758

INT

ER

ME

DIA

TE

CA

RR

IER

AS

SE

MB

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129

6952

SP

RA

G B

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KE

HU

B A

SS

EM

BLY

41

2967

57IN

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T C

AR

RIE

R A

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BLY

414

4320

23F

ITT

ING

JIC

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2997

49B

AN

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421

4380

43B

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CO

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R6

130

3146

LH M

OU

NT

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130

3147

RH

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G A

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101

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151

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161

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4320

53F

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171

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45G

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542

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, -8

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IDE

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7186

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143

2054

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231

3571

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PARTS LIST

18

402

402

409

403

404

406

404

401

405

404

406

403

407

408

ITE

M

ITE

M

QTY

QTY

PA

RT N

OP

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2418067

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2418223

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3424005

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TTER

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X 1

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405

1424027

CLE

VIS

PIN

-1/2

SH

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DIA

X 1

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406

2424205

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1433031

AIR

CYLI

ND

ER

408

1433032

AIR

CYLI

ND

ER

409

1448108

EYE B

OLT

AIR CYLINDER KIT #256131 PARTS LIST

19

Bo

lt Si

ze

(inc

hes)

Thds

Per

In

ch

SAE

Grad

e 5

SAE

Grad

e 8

7/1

614

5478

1/2

13

7811

9 5

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1115

423

0 3

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1025

738

0 7

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938

260

01

858

770

0

Bolt

Torq

ue (f

t-lb

)

DIMENSIONAL DRAWING WC 65K

14.

75

6.0

0

4.8

9

60.

00

8.

00

19

.00

19.

38

13.

36

46.

97

14.

50

27.

94

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DRU

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Limited Warranty RAMSEY WINCH warrants each new RAMSEY Wildcat Winch to be free from defects in material and workmanship for a period of two (2) years from the date of purchase. Our new two year limited warranty is standard equipment on all Wildcat Winches manufactured after July 4th, 2014, and is also available for all Wildcat series winches currently in inventory at authorized distributors if the model and serial numbers are submitted to Ramsey Winch by August 30, 2014. End users who have purchased a winch since June 1, 2014, are also eligible for the two year warranty with purchase date, serial number, and model number submitted to an approved Wildcat Distributor by August 30, 2014.

Warranty General. 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 repairs or alterations have been made unless authorized by the Manufacturer, or for equipment misused, neglected or which has not been installed correctly.

To the fullest extent permitted by applicable law, the following are hereby excluded and disclaimed: 1.All warranties of fitness for a particular purpose; 2. All warranties of merchantability; 3. All claims for consequential or incidental damages. There are no warranties that extend beyond the description that appears on the face hereof. Some states do not allow the above exclusions or disclaimers in consumer transactions and as such this disclaimer/exclusion may not apply to your particular case. To the extent such warranties of fitness for a particular purpose or merchantability are deemed to apply to this product, they exist for only so long as the express limited warranty elsewhere set forth is in existence.

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 of 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.

This Warranty gives you specific legal rights and you may also have other legal rights, which vary from state to state.

Ramsey Winch CompanyPost Offi ce Box 581510

Tulsa, Oklahoma 74158-1510Telephone: (#918) 438-2760 FAX: (#918) 438-6688