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Ramsey Winch POWERMASTER SERIES 20,000 LB Operating, Service And Maintenance Manual

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OPERATING, SERVICE AND
MAINTENANCE MANUAL
POWERMASTER SERIES 20,000 LB
INDUSTRIAL WINCH AND BUMPER
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF
WINCH. SEE WARNINGS!

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Summary of Contents for Ramsey Winch POWERMASTER SERIES 20,000 LB

  • Page 1 OPERATING, SERVICE AND MAINTENANCE MANUAL POWERMASTER SERIES 20,000 LB INDUSTRIAL WINCH AND BUMPER CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE WARNINGS!

  • Page 2: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ......................1 WARRANTY INFORMATION .................... 1 SPECIFICATIONS ......................1 WARNINGS ........................1 CABLE INSTALLATION ....................2 HYDRAULIC SYSTEM REQUIREMENTS ................3 PERFORMANCE CHARTS ....................3 CLUTCH OPERATION ..................... 4 WINCH OPERATION ....................... 4 MAINTENANCE ......................4-5 TROUBLESHOOTING GUIDE ....................

  • Page 3: Introduction

    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.

  • Page 4: Cable Installation

    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 into hole in cable drum as shown below. Use 3/8”-16NC X 3/8” Lg. Hx socket drive setscrew to secure cable to drum.

  • Page 5: Hydraulic System Requirements

    HYDRAULIC SYSTEM REQUIREMENTS Refer to the performance charts, below, to properly match your hydraulic system to the Powermaster 20K 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).

  • Page 6: Clutch Operation

    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.

  • Page 7: Troubleshooting Guide

    C. ANNUALLY Drain the oil from the winch annually or more often if winch is used frequently. 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. Refill the winch to the oil level plug with all purpose SAE W- 0 Inspect bumper and surrounding structure for cracks or deformation.

  • Page 8: Instructions For Disassembly

    INSTRUCTIONS FOR DISASSEMBLY 1. NOTE: Removal of winch from bumper will require 2 persons. Winch must be lowered through the bottom of bumper. Do not attempt to lift winch out through the top of bumper. 2. NOTE: Winch must be supported prior to removing winch mounting bolts. 3.
  • Page 9 4. Remove vertical roller pin #120 from right hand side of roller guide #102 by removing spring pin #119. Spring pins should be removed by driving inward through the roller. Vertical roller pin has (2) lube fittings #118 located one at either end of the roller. Once the vertical roller pin is removed from right hand side of roller guide, vertical roller #117 can be removed.
  • Page 10 INSTRUCTIONS FOR OVERHAUL – 20K Powermaster Winch Drain oil from gear housing by removing plug #65 from drain hole in end bearing. When refilling oil in gear housing, use 16 ounces of SAE W- 0 Freespool drum to locate drain hole in bottom. Remove plugs #47 from barrel of drum. Drain oil from drum barrel.
  • Page 11 3. Loosen (6) capscrews #27 and remove clutch housing cover #7. Remove relief fitting #36 and plug #46 from clutch housing cover as shown. Remove shaft oil seal #54; also remove clutch housing o-ring #44 and bushing #21. Pull shifter lever away from drum and slide clutch yoke #18 from shaft.
  • Page 12 4. Slide clutch end bearing #2 from drum. Drum freespool drag puck #12, drum freespool spring # 58, and brake disc spacer # 62 will fall out when end bearing is removed from drum. Retain these items for re-assembly. To remove shifter yoke #19, drive spring pin #50 inward through shifter yoke. Lift shifter assembly out by pulling up on shifter handle assembly #17 until shifter shaft #15 is clear of shifter yoke #19.
  • Page 13 5. Remove drum bushing assembly #22. Note that the (6) spring pins #53 are pressed into the bushing and cannot be removed. To replace the drum bushing, first press in the (6) spring pins #53, and then replace the bushing. Drum seal #55 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.
  • Page 14 6. 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 #49 inward to center of input carrier assembly #6. Remove (3) input planet pins #52 from input carrier assembly #6. Remove (3) input planet gears #4 from input carrier assembly #6.
  • Page 15 7. Remove drum #13 from motor end bearing #3. Remove drum seal #55. Check for signs of wear and replace if necessary. 8. Remove input shaft #14 from motor end bearing #3. 9. To remove motor #37 from motor end bearing #3, first detach hydraulic brake release hose assembly #64 from elbow fitting #33 and #34.
  • Page 16 11. Remove (2) retaining rings #56. Remove motor coupling #32 from end bearing #3. Remove roll pin #48 from motor coupling #32. Remove brake piston #10 and backup brake piston #11. Remove o-ring #39, o-ring #38, backup ring #41, and backup ring #43 from brake piston #10. Remove o-ring #40 and backup ring #42 from backup brake piston #11.

  • Page 17: Parts List And Part Drawing

    PARTS LIST – POWERMASTER 20K BUMPER WINCH PART NO DESCRIPTION ITEM QTY. 296654 20K BUMPER WINCH PORTS DOWN 296680 20K BUMPER WINCH PORTS UP 333026 ROLLER GUIDE-RH 333027 ROLLER GUIDE-LH 410010 BUM PER-BLACK 414550 BOLT-1/2-13NCX1 3/4LG,HXHD,Z/P,GR.8 414961 CAPSCREW-1/2-13NC X 1.25 LG HX HD GR8 Z/P 414512 CAPSCREW-1/2-13NC X 1.25 LG HX HD GR8 Z/P...
  • Page 18 POWERMASTER * CONFIRM MOTOR PORTS UP OR MOTOR PORTS DOWN FOR CORRECT HOSE ASSEMBLY 20K BUMPER WINCH...
  • Page 19 PARTS LIST – POWERMASTER 20K BUMPER WINCH ITEM QTY. PART NO DESCRIPTION ITEM QTY. PART NO DESCRIPTION 247040 OUTPUT CARRIER 432018 FITTING-90 DEGREE ELBOW, -4 SAE ORING TO -4 JIC 296673 CLUTCH END BEARING 432044 FITTING-45 DEGREE ELBOW, -4 SAE ORING TO -4 JIC 296674 MOTOR END BEARING 442223 GASKET-MOTOR 296675 INPUT PLANET GEAR ASSEMBLY...

  • Page 20: Limited Warranty

    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...

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