Ramsey Winch POWERMASTER 20, 000 LB, Powermaster 15, 000 Operating, Service And Maintenance Manual
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
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 ............................................................................................ 5
INSTRUCTIONS FOR DISASSEMBLY ................................................................................ 6-14
PARTS LIST AND PART DRAWING ................................................................................... 15-17
LIMITED WARRANTY ..................................................................................................... 18
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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.
Rated Line Pull (lbs.) …………………………………………………………………………. 20,000
(Kg.) …………………………………………………………….. 9070
Gear Reduction ……………………………………………………………… 21:1
Weight (without cable) 20K Bumper Winch (Less Bumper)… ………….…………. 337 lbs
LAYER OF CABLE 1 2 3 4 5
*Rated line pull
per layer
* Cable Capacity per Layer
20K Winch
* Line Speed
(at 30 GPM)
* These specifications are based on recommended wire rope of 9/16" Extra Improved Plow
Steel and a 14.9 cu. in. / Rev. motor.
lbs. 20,000 17,300 15,200 13,600 12,300
Kg. 9,070 7,840 6,890 6,160 5,570
ft. 30 70 115 165 220
m 9 21 35 20 67
FPM 42 47 53 59 65
MPM 12.1 13.6 15.5 17 18.8
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.
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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
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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
0 500 1000 1500 2000 2500
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
0 5 10 15 20 25 30
LOW PRESSURE LINE
PUMP
FLOW,GPM
3
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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 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.
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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 W-0 6\QWKHWLF*ear 2il.
4. Inspect bumper and surrounding structure for cracks or deformation.
TROUBLESHOOTING 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 (open
valve. (Cylinder spool, closed center) directional control
center). valve.
5
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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. 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
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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. Remove
vertical roller from left hand side of roller guide in the same way.
117
119
102
120
5. 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
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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 W-0 6\QWKHWLF*HDU2il.
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 W-06\QWKHWLF
*HDU2LO5HPRYHmounting angle #5 by loosening (3) capscrews #25 each side.
5
25
25
8
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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
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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. 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
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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
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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
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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
24
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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 W-0
Synthetic Gear 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.
34
3
DRUM SIDE MOTOR SIDE
8
9
42
38
43
11
11
40
SECTION A-A
42
40
39
41
10
43
38
10
39
A
A
41
32
56
48
14
Page 17
15
PARTS LIST – POWERMASTER 20K BUMPER WINCH
101
111
110
106
112
118
118
120
112
118
102
119
114
117
116
111
103
118
120
118
117
119
114
111
108
108
118
ITEM QTY.
PART NO
DESCRI PTI ON
101 1 2966 54 20K BUMPER WINCH PORTS DOWN
1 29668
0
20K BUMP ER WINCH PORTS U
P
102 1 3330 26 ROLLE R GUIDE- RH
103 1 3330 27 ROLLE R GUIDE- LH
106 1 410 01
0
BUMPER-BL ACK
108 4 4145 50 BOL T-1/ 2-1 3NCX1
3/4 LG
,
HXHD,Z/P,GR.8
110 6 414961 CAPSCREW-1 /2-13 NC X 1.25 LG HX HD
GR8 Z/
P
111 10 414512 CAPSCRE W-1/2- 13NC X 1. 25 LG HX HD
GR8 Z/
P
112 6 418 069NUT-1/2- 13NC HEX REG,ZI NC PLATE
D
114 6 418218 L OCKWASHER- 1/2 I D MED SECT, ZINC
PLT
116
2
424033ROLLE R-HORI ZONTA L
117
2
4240 34 ROL LER -VERT IC AL
118
8
4560 01 LUBE FI TTIN
G
119
2
470105SPRI NG PIN
120
2
470109VERTICAL ROLLER PI N
SIZE TORQUE VALUE
1/4-20
76 IN LBS
3/8-16
23 FT LBS
1/2-13
57 FT LBS
3/4-16 223 FT LBS
SIZE TORQUE VALUE
1/2-13
80 FT LBS
5/8-11 159 FT LBS
GRADE 5
GRADE 8
TORQUE VALUE CHART
Page 18
16
28
33
60
43
38
39
41
32
56
24
37
35
59
48
10
40
11
53
22
55
2
12
58
62
65
50
19
65
51
15
45
17
20
18
44
7
54
27
36
21
31
23
26
30
46
8
42
9
34
3
25
5
25
55
14
29
47
46
47
13
6
57
52
49
4
52
49
4
52
49
4
61
1
16
64
63
*
* CONFIRM MOTOR PORTS UP OR MOTOR PORTS DOWN
FOR CORRECT HOSE ASSEMBLY
POWERMASTER
20K BUMPER WINCH
Page 19
ITEM QTY. PART NO DESCRIPTION ITEM QTY. PART NO DESCRIPTIO N
1 1 24 7040 OUTPUT CARRI ER 33 1 432018 FITTI NG-90 DEGREE ELBOW, - 4 SAE ORI NG TO -4 JIC
2 1 29 6673 CLUTCH END BEA RIN
G
341 432044FITTING-45 DEGREE ELBOW, -4 S AE ORING TO -4 JIC
3 1 29 667
4
MOT OR E ND B EARI N
G
351 442223 GA SKET-MOT OR
4
3 29 6675INPUT PLANET GEAR ASSEMBLY 36 1 456008 RELIE F FITTING
5
1 30 3127 ANG LE-T OW 37 1 458144MOTOR- HYD (14 .9) CU I N 1" SHAF
T
6 1 31 7015CARRIER-INPU
T
38 1 462067 O-RING-2.22 5 ID X .210 THK, 2-331
7 1 328166 COVER-CLUTCH HOUSIN
G
39 1 462068 O-RING-3.10 ID X . 210 THK, 2-338
8 7 33 0011 ST ATOR-BR AK
E
40 1 462069 O-RING-2.97 5 ID X .210 THK, 2-337
9 6 33 0012 DISC-BRAKE FRICTION 41 1 462070 RING-BACKUP, 3.143 ID X .076 THK , 8-338
10 1 330013 PI STON-B RAK
E
42 1 462071 RING-BACKUP, 3.018 I D X .076 THK , 8-337
11 1 33001
4
PI STON-BA CKUP BRAK
E
43 1 462072 RING-BACKUP, 2.268 I D X .076 THK , 8-331
12 1 33001
5
PUCK-DRAG, DRUM FREESPOOL 4
4
1 462077 O-RING-6.98 4 ID X .139 THK, 2-262, CLUTCH HSG CVR
13 1 332231 DRUM- MACHINED 4
5
1 462078 O-RING-.549 ID X .103 THK, 2 -113, SHIF TER S HAF
T
14 1 355139 S HAFT-I NPU
T
46 2 468016 PLUG-PIPE 1/8 -27NPTF S OC HD
15 1 355141 SHA FT -SH IFTER 47 2 46 8041 PLUG, -8 SAE, 3/4"-16 UNF
16 1 35514
4
SHAFT-OUTPU
T
48 1 470033 SPIROL PI N
17 1 296682 SHI FT LEVER ASSEMBLY 49 3 470060 SPRING PIN-3/16 X 1/ 2 L
G
18 1 370065CLUTCH-YOK
E
50 1 470103 PI N- SPRI NG, .25 X 1.0 L
G
19 1 370061 Y OKE-SHI FTE R 51 1 470104PI N- SPRING, .25 X 1.5 L
G
20 1 408364BRACKET-SHIFTER DETEN
T
52 3 470107 PI N- INPUT PLANET
21 1 41211
5
BUSHI NG-CLUTCH HOUSING COVER 53 6 470123 PI N- SPRI NG, .188 X 1. 00 LG
22 1 412132 BUS HING- DRUM 5
4
1 486066 SEAL-S HAFT OIL
23 2 414038 CAPSCREW-1/4- 20NC X .75 L G HX HD GR5 Z/P 5
5
2 486093 S EAL-DRUM
24 2 414511 CAPSCREW-1/2- 13 X 2.0 L G SOC HD 56 2 490049 RING-INTERNAL RETAININ
G
25 6 414513 CAPSCREW-1/2- 13UNC X 2.00 LG HX HD GR8 Z/P 57 1 490061 RING-EXTERNAL RETAI NING, OUTPUT S HAF
T
26 1 414772 CAPSCREW-3/4- 16NF X 2.0 LG HX HD GR
5
58 1 494002 SPRING-DRUM FREESPOOL
27 6 414906 CAPSCREW-3/8- 16NC X 1.5 L G SOC HD F/B 59 11 49 412
4
SPRING-BRAKE
28 3 41 493
5
CAPSCREW-3/8- 16NC X 2.5 LG SOC HD 60 1 51 6011 VALVE-MOTOR CONT ROL
29 1 416057 SETSCREW-3/ 8-16NCX3/ 8LG, HX SOCH D CU 61 1 51 8071 THRUST WAS HER
30 1 418098 NUT-3/4 -16NF HEX JAM 6 2 1 53009
4
SPACER-BRAKE DISC
31 2 418149 LOCKWASHER- 1/4 MED SE CTION,ZINC PL
T
63 1 50 9130 HOSE ASSEMBLY - PORTS DOWN
32 1 43 1023 COUPL ING-MOT OR 6
4
1 50 9142 HOSE ASSEMBLY - PORTS UP
6
5
2 46 8018 PLUG - 3/ 8" -18 NPTF HX SOC
17
PARTS LIST – POWERMASTER 20K BUMPER WINCH
Page 20
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.
Telephone: (918) 438-2760 FAX: (918) 438-6688
Ramsey Winch Company
Post Office Box 581510
Tulsa, Oklahoma 74158-1510
OM-914246-1209-A
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