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ITEM  QTY. PART NO DESCRIPTION

ITEM  QTY. PART NO DESCRIPTION

1

1

247040 OUTPUT CARRIER

33

1

432018 FITTING-90 DEGREE ELBOW, -4 SAE ORING TO -4 JIC

2

1

296673 CLUTCH END BEARING

34

1

432044 FITTING-45 DEGREE ELBOW, -4 SAE ORING TO -4 JIC

3

1

296674 MOTOR END BEARING

35

1

442223 GASKET-MOTOR

4

3

296675 INPUT PLANET GEAR ASSEMBLY

36

1

456008 RELIEF FITTING

5

1

303127 ANGLE-TOW

37

1

458144 MOTOR-HYD (14.9) CU IN 1" SHAFT

6

1

317015 CARRIER-INPUT

38

1

462067 O-RING-2.225 ID X .210 THK, 2-331

7

1

328166 COVER-CLUTCH HOUSING

39

1

462068 O-RING-3.10 ID X .210 THK, 2-338

8

7

330011 STATOR-BRAKE

40

1

462069 O-RING-2.975 ID X .210 THK, 2-337

9

6

330012 DISC-BRAKE FRICTION

41

1

462070 RING-BACKUP, 3.143 ID X .076 THK, 8-338

10

1

330013 PISTON-BRAKE

42

1

462071 RING-BACKUP, 3.018 ID X .076 THK, 8-337

11

1

330014 PISTON-BACKUP BRAKE

43

1

462072 RING-BACKUP, 2.268 ID X .076 THK, 8-331

12

1

330015 PUCK-DRAG, DRUM FREESPOOL

44

1

462077 O-RING-6.984 ID X .139 THK, 2-262, CLUTCH HSG CVR

13

1

332231 DRUM-MACHINED

45

1

462078 O-RING-.549 ID X .103 THK, 2-113, SHIFTER SHAFT

14

1

355139 SHAFT-INPUT

46

2

468016 PLUG-PIPE 1/8-27NPTF SOC HD

15

1

355141 SHAFT-SHIFTER

47

2

468041 PLUG, -8 SAE, 3/4"-16 UNF

16

1

355144 SHAFT-OUTPUT

48

1

470033 SPIROL PIN

17

1

296682 SHIFT LEVER ASSEMBLY

49

3

470060 SPRING PIN-3/16 X 1/2 LG

18

1

370065 CLUTCH-YOKE

50

1

470103 PIN-SPRING, .25  X 1.0 LG

19

1

370061 YOKE-SHIFTER

51

1

470104 PIN-SPRING, .25  X 1.5 LG

20

1

408364 BRACKET-SHIFTER DETENT

52

3

470107 PIN-INPUT PLANET

21

1

412115 BUSHING-CLUTCH HOUSING COVER

53

6

470123 PIN-SPRING, .188  X 1.00 LG

22

1

412132 BUSHING-DRUM

54

1

486066 SEAL-SHAFT OIL

23

2

414038 CAPSCREW-1/4-20NC X .75 LG HX HD GR5 Z/P

55

2

486093 SEAL-DRUM

24

2

414511 CAPSCREW-1/2-13 X 2.0 LG SOC HD

56

2

490049 RING-INTERNAL RETAINING

25

6

414513 CAPSCREW-1/2-13UNC X 2.00 LG HX HD GR8 Z/P

57

1

490061 RING-EXTERNAL RETAINING, OUTPUT SHAFT

26

1

414772 CAPSCREW-3/4-16NF X 2.0 LG HX HD GR5

58

1

494002 SPRING-DRUM FREESPOOL

27

6

414906 CAPSCREW-3/8-16NC X 1.5 LG SOC HD F/B

59

11

494124 SPRING-BRAKE

28

3

414935 CAPSCREW-3/8-16NC X 2.5 LG SOC HD

60

1

516011 VALVE-MOTOR CONTROL

29

1

416057 SETSCREW-3/8-16NCX3/8LG,HX SOCHD CU

61

1

518071 THRUST WASHER

30

1

418098 NUT-3/4-16NF HEX JAM

62

1

530094 SPACER-BRAKE DISC

31

2

418149 LOCKWASHER-1/4 MED SECTION,ZINC PLT

63

1

509130 HOSE ASSEMBLY - PORTS DOWN

32

1

431023 COUPLING-MOTOR

64

1

509142 HOSE ASSEMBLY - PORTS UP

65

2

468018 PLUG - 3/8" -18 NPTF HX SOC

 

 

 

 

 

 

 

 

 

 

 

17 

PARTS LIST – POWERMASTER 20K BUMPER WINCH 

 

  

Summary of Contents for POWERMASTER SERIES 20,000 LB

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

Page 2: ...FICATIONS 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 DISASSEMB...

Page 3: ...ed 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 MOTO...

Page 4: ...lly 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 oper...

Page 5: ...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...

Page 6: ...e 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 yo...

Page 7: ...TING 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 D...

Page 8: ...ugh 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...

Page 9: ...side of roller guide vertical roller 117 can be removed Remove vertical roller from left hand side of roller guide in the same way 5 The two horizontal rollers 116 are held in place by the roller gui...

Page 10: ...bearing When refilling oil in gear housing use 16 ounces of SAE W 0 6 QWKHWLF HDU 2il 2 Freespool drum to locate drain hole in bottom Remove plugs 47 from barrel of drum Drain oil from drum barrel Whe...

Page 11: ...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 slid...

Page 12: ...embly 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 remov...

Page 13: ...sed 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 Re...

Page 14: ...m 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 R...

Page 15: ...first detach hydraulic brake release hose assembly 64 from elbow fitting 33 and 34 Loosen 2 13 capscrews 24 Remove motor gasket 35 and 11 brake springs 59 10 To remove motor control valve 60 loosen 3...

Page 16: ...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...

Page 17: ...0 BOLT 1 2 13NCX1 3 4LG HXHD Z P GR 8 110 6 414961 CAPSCREW 1 2 13NCX1 25LGHXHD GR8Z P 111 10 414512 CAPSCREW 1 2 13NCX1 25LGHXHD GR8Z P 112 6 418069 NUT 1 2 13NCHEXREG ZINCPLATED 114 6 418218 LOCKWAS...

Page 18: ...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 D...

Page 19: ...7 2 468041 PLUG 8 SAE 3 4 16UNF 16 1 355144 SHAFT OUTPUT 48 1 470033 SPIROLPIN 17 1 296682 SHIFT LEVERASSEMBLY 49 3 470060 SPRINGPIN 3 16 X1 2 LG 18 1 370065 CLUTCH YOKE 50 1 470103 PIN SPRING 25 X1 0...

Page 20: ...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 co...

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