* These specifications are based on recommended wire rope of 9/16" Extra Improved Plow
Steel and a 14.9 cu. in. / Rev. motor.
RAMSEY HYDRAULIC PLANETARY WINCH MODEL POWERMASTER 20K
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*
NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.
CAPSTAN RATING IS 3,000 LBS BASED ON 7” DRUM BARREL.
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.
1 OM-914206-0112-C
CAPSTAN SAFEGUARDS AND OPERATION
CAUTION: THE CAPSTAN OPERATES IN THE OPPOSITE DIRECTION OF THE WINCH DRUM. CONFIRM
CAPSTAN ROTATION PRIOR TO OPERATION.
The winch is equipped with a dual brake valve cartridge; therefore, the capstan may be operated in
either direction. The rope can be wrapped around the capstan in either direction.
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.
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 #30 and turn 3/8”-16NC capscrew #26 clockwise to
increase drag on drum. If cable pull is excessive, loosen 3/8”-16NC capscrew #26 by turning
counterclockwise. Tighten jam nut when proper setting is obtained.
SETSCREW
INSERT CABLE AS SHOWN
30
26
2 OM-914206-1208-B
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). Performance based on a motor displacement of 14.9 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.
TYPICAL LAYOUT
DUAL-A & B PORT CONTROL
WITH BRAKE RELEASE SHUTTLE
MOTOR
BRAKE
PORT
A
B
PERFORMANCE CHARTS
20000
15000
10000
FIRSTLAYER
LINEPULL,LBS
5000
BASED ON 14.9 CU IN/REV MOTOR
0
05001000150020002500
WORKINGPRESSURE,PSI
HIGH PRESSURE LINE
CONTROL VALVE
3 POSITION
4 WAY VALVE
(MOTOR SPOOL)
45
40
35
30
25
20
FIRSTLAYER
15
LINESPEED,FT/MIN
10
5
0
051015202530
LOW PRESSURE LINE
PUMP
FLOW,GPM
3 OM-914206-1208-B
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 aw ay 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 confidence 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
Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and
1.
repair.
2.
Check the pressure relief plug on the gear housing cover. Be sure that it is not plugged.
3. 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.
4 OM-914206-1208-B
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 SAE 80W-140 gear oil.
4. Inspect bumper and surrounding structure for cracks or deformation.
BRAKE WLL NOT HOLD1. Incorrect directional control 1. Use only a motor spool (open
valve. (Cylinder spool, closed center) directional control
center). valve.
5 OM-914206-1208-B
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. To remove the winch from the bumper, it will be necessary to first disconnect the capstan drive
shaft # 105 from the winch by removing (1) 5/8-11UNC capscrew #109. Pull capstan drive
shaft out through hole in end of bumper. If it is necessary to remove the pillar block # 104,
remove (2) capscrews # 110 from front and (2) capscrews #110 from back side of bumper,
pillar block can then be removed from the underside of the bumper.
110
109
105
104
106
101
3. NOTE: Winch must be supported prior to removing winch mounting bolts.
4. Remove (6) capscrews #110 from back side of bumper as shown below. Next remove (4)
capscrews # 111 from back side of bumper. Remove (4) capscrews #108 from front side of
bumper. Once these capscrews are removed, the winch can be removed from the underside of
bumper.
111
110
111
110
101
108
108
106
6 OM-914206-1208-B
5. 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. Remove
vertical roller from left hand side of roller guide in the same way.
117
119
102
120
6. The two horizontal rollers #116 are held in place by the roller guides and can now be removed.
Each horizontal roller has (2) lube fittings #118, located one at either end of the roller. To
remove the right hand roller guide #102, and the left hand roller guide #103 remove (3)
capscrews #111, (3) washers #114, and (3) nuts #112 each side.
112
112
114
111
118
103
116
111
102
114
7 OM-914206-1208-B
INSTRUCTIONS FOR OVERHAUL – 20K Powermaster Winch
1. 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 80W-140 oil.
65
2. Freespool drum to locate drain hole in bottom. Remove plugs #47 from barrel of drum. Drain oil
from drum barrel. When refilling oil in drum, use 16 ounces of SAE 80W-140. Remove
mounting angle #5 by loosening (3) capscrews #25 each side.
5
25
8 OM-914206-1208-B
25
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.
18
44
36
27
54
46
21
7
9 OM-914206-1208-B
4. Slide clutch end bearing #2 from drum. Drum freespool drag puc k #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. Yoke can then be lifted out of end bearing.
To replace handle #17 on shifter shaft #15, first remove spring pin #51, then slide handle
assembly #17 from shifter shaft #15. O-ring #45 can be replaced at this time.
To replace shifter detent bracket #20, first remove (2) ¼ x 20 capscrews #23 and (2) ¼
lockwashers # 31, then remove shifter detent bracket #20 and replace.
17
45
50
19
51
15
2
62
12
58
65
46
30
26
23
31
20
10 OM-914206-1208-B
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.
55
22
53
11 OM-914206-1208-B
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.
Remove output shaft external retaining ring #57 from output shaft #16. Slide input carrier #6 f
rom output shaft #16.
Remove thrust washer #61 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.
16
1
61
6
49
4
52
49
4
52
4
49
57
52
13
12 OM-914206-1208-B
7. Remove drum #13 from motor end bearing #3. Remove drum seal #55. Check for signs of
wear and replace if necessary.
13
55
8. Remove input shaft #14 from motor end bearing #3.
14
3
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. Loosen (2) ½-13 capscrews #24. Remove motor
gasket #35, and (11) brake springs #59.
10. To remove motor control valve #60, loosen (3) 3/8-16 NC capscrews #28. Lift motor control
valve #60 from motor #37.
Note: Do not run winch with hydraulic brake release hose assembly disconnected.
64
3
33
TO ITEM 34
28
TO ITEM 33
64
34
59
35
60
37
13 OM-914206-1208-B
24
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. 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 #48 into motor coupling #32 below bottom of spline teeth. Insert motor coupling
#32 into end bearing #3.
Install (2) retaining rings #56 into grooves in motor end housing.
3
8
34
9
42
38
43
DRUM SIDEMOTOR SIDE
11
11
40
SECTION A-A
42
40
39
41
10
43
38
10
A
A
39
41
32
56
48
14 OM-914206-1208-B
PARTS LIST – POWERMASTER 20K BUMPER WINCH
/
101
15
105
109
110
ITEM QT Y.
PART NO
101129665420 K BUMPER WINCH PORTS DOWN
1296 68020K BUMPER WINCH PORTS UP
1021333026ROLLER GUIDE-RH
1031333027ROLLER GUIDE-LH
1041296676PILL AR BLOCK
1051296679CA PSTAN DRIVE SH AFT A SSEM BLY
1061410010BUMPER-BLACK
1084414550BOLT-1/2-13 NCX1
1091414672CA PS CREW-5/8-11UNC X 3.5 0 L G HX
11010414 961CAPSCREW-1/2-13NC X 1. 25 LG HX H D
11110414 512CAPSCREW-1/2-13NC X 1. 25 LG HX H D
1126418069NUT-1 /2- 13NC HEX REG,ZINC PLATED
1131418080NUT-5 /8- 11NC REG HEX,ZINC PLATED
1146418218L OCKWASH ER-1/2 ID MED SE CT,ZI NC
1152418223WASHER-1/2 USS FL AT,ZI NC PLATED
1162424033ROLLER-HORIZONTAL
1172424034ROLLER-VERTICAL
1188456001L UBE FITTING
1192470105SPRI NG PIN
1202470109VERTICA L ROLLER PIN
DESCRIPTION
3
4LG,HXHD,Z/P,GR.8
HD GR8 Z/P
GR8 Z/P
GR8 Z/P
PLT
113
115
111
114
118
108
119
117
104
118
120
110
112
103
111
106
110
118
118
120
118
118
112
TORQUE VALUE CHART
GRADE 5
SIZETORQUE VALUE
1/4-20
3/8-16
1/2-13
76 IN LBS
23 FT LBS
57 FT LBS
3/4-16223 FT LBS
GRADE 8
SIZETORQUE VALUE
1/2-13
80 FT LBS
5/8-11159 FT LBS
111
116
117
114
119
102
108
16
36
27
16
1
61
4
49
52
4
4
49
49
52
6
25
52
57
47
13
5
46
47
44
29
55
14
3
25
54
34
21
7
31
23
26
9
30
18
42
20
46
19
50
8
40
11
65
10
65
43
62
17
58
38
15
45
12
51
41
2
55
22
53
28
39
33
32
60
56
POWERMASTER
20K BUMPER WINCH
*
63
64
* CONFIRM MOTOR PORTS UP OR MOTOR PORTS DOWN
FOR CORRECT HOSE ASSEMBLY
48
59
35
37
24
G
4
4
G
5
4
5
T
T
G
E
E
4
E
5
4
5
T
T
4
T
G
E
G
G
T
5
4
5
G
T
5
4
5
4
T
4
5
17
PARTS LIST – POWERMASTER 20K BUMPER WINCH
ITEM QTY.PART NO DESCRIPTIONITEM QTY.PART NO DESCRIPTION
11247040OUTPUT CARRIER331432018FITTING-90 DEGREE ELBOW, -4 SAE ORING TO -4 JIC
21296673CLUTCH END BEARIN
3129 667
329 6675INPUT PLANE T GEAR ASSEMBLY361456008RELIE F FI TTI NG
130 3127ANGL E-TOW371458144MOTOR- HYD (14.9) CU I N 1" SHAF
6131 7015CARRIER-INPU
71328166COVER-CLUTCH HOUSIN
8733 0011STATOR-BRA K
96330012DISC-BRAKE FRICTI ON41146 2070RI NG-BACKUP, 3.143 ID X .076 THK, 8- 338
10133001 3 PISTON-BRAK
11133001
12133001
13133223 1 DRUM-MACH INED4
14135513 9 SHAFT-I NPU
151355141SHAFT-SHIFTER472468041PLUG, -8 SAE, 3/4"-16 UNF
16135514
171296682SHIFT LEVER ASSEMBLY493470060S PRI NG PI N-3/16 X 1/2 L
181370065CLUTCH-YOK
19137006 1 YOKE- SHIFTER511470104PI N-SPRI NG, .25 X 1.5 L
201408364BRACKET-SHIFTER DETEN
21141211
22141213 2 BUSHI NG-DRUM5
232414038CAPSCREW-1/4-20NC X .75 LG HX HD GR5 Z/P5
242414511CAPSCREW-1/2-13 X 2.0 LG SOC HD562490049RING-INTE RNAL RETAI NIN
256414513CAPSCREW-1 /2- 13UNC X 2.00 LG HX HD GR8 Z/P571490061RING-EX TERNAL RETAI NING, OUTPUT S HAF
261414772CAPSCREW-3 /4- 16NF X 2.0 LG HX HD GR
276414906CAPSCREW-3/8-16NC X 1.5 LG SOC HD F/B591149412
28341493
291416057SETSCREW-3/ 8-16NCX3/ 8LG,HX SOCHD CU611518071THRUST WASHER
301418098NUT-3/4 -16NF HEX JAM62153009
312418149LOCKWASHER-1/4 MED SECTI ON,ZINC PL
32143102 3 COUPLING-MOTOR6
MOT OR END BEAR I N
PI ST ON-BACKUP BRAK
PUCK-DRAG, DRUM FREESPOOL4
SHAFT-OUTPU
BUSHI NG-CLUTCH HOUSI NG COVER536470123PIN-SPRING, .188 X 1.00 LG
CAPSCREW-3 /8- 16NC X 2.5 LG SOC HD601516011VALVE-MOTOR CONTROL
3
3
381462067O- RING-2.225 I D X .210 THK, 2-331
391462068O- RING-3.10 ID X .210 THK, 2-3 38
401462069O- RING-2.975 I D X .210 THK, 2-337
421462071RING-BACKUP, 3.018 I D X .076 THK , 8- 337
431462072RING-BACKUP, 2.268 I D X .076 THK , 8- 331
462468016PLUG-PIPE 1/8 -27NPTF SOC HD
481470033S PI ROL PIN
501470103PIN-SPRING, .25 X 1.0 L
523470107PIN-INPUT PLANET
581494002S PRI NG-DRUM FREESPOOL
631509130HOSE ASSEMBLY - PORTS DOWN
6
1432044FITTING-45 DEGREE ELBOW, -4 SAE ORING TO -4 JIC
1442223GASKET- MOT OR
1462077O-RING- 6.98 4 I D X .139 THK, 2-262, CLUTCH HSG CVR
1462078O-RING- .549 ID X .103 THK, 2-1 13, S HIF TER SHAF
1486066S EAL-SHAF T OIL
2486093S EAL-DRUM
SPRING-BRAKE
SPACER-BRAKE DISC
1509142H OSE ASSEMBLY - PORTS UP
2468018PLUG - 3/ 8" -18 NPTF HX SOC
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
Post Office Box 581510
Tulsa, Oklahoma 74158-1510
Telephone: (918) 438-2760 FAX: (918) 438-6688
OM-914206-1208-B
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