Ramsey Winch H-89 User manual

OM-914228-1113-C
OPERATING, SERVICE,
AND
MAINTENANCE MANUAL
Ramsey Winch Company
P.O. Box 581510 - Tulsa, OK 74158-1510 USA
Phone: [phone] - Fax [phone]
Visit us at http://www.ramsey.com
INTENDED USE: VEHICLE RECOVERY AND PULLING OF LOADS
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION
OF WINCH. SEE WARNINGS!
MODEL H-89 WINCH
English (Original Instructions)…………………….. 1
Francais (Translation of the Original Instructions)…. 25
Deutsch (Translation of the Original Instructions)….. 48
Espanol (Translation of the Original Instructions) …. 72
Ramsey Authorized Representative in the Community:
(Please contact for regulatory inquiries only.)
Alura Group BV
P.O. Box 18626
2502 EP The Hague
The Netherlands
Tel: (31) (0) 70 362-4896
Fax: (31) (0) 70 346-7299

OM-914228-1113-C

3
Contents
Warnings .................................................................................................. 3
User’s Responsibility for CE Compliance .................................................. 3
Techniques of Operation ...................................................................... 4-5
Winch Maintenance .................................................................................. 5
Winch Mounting ........................................................................................ 5
Rope Installation ....................................................................................... 6
Adjusting the Oil Cooled Holding Brake .................................................... 7
Servicing the Oil Cooled Holding Brake .................................................... 7
Re-assembling and Checking the Brake .................................................. 8
Test of Proper Brake Assembly ............................................................... 8
Adjustment of Clutch Air Shifter ................................................................ 9
Troubleshooting Guide .......................................................................... 10
Hydraulic System Requirements ............................................................ 11
Typical Hydraulic Layout ........................................................................ 11
Performance Charts................................................................................. 12
Instructions for Overhaul .................................................................... 13-17
Dimensional Drawings ....................................................................... 18-19
Parts Drawings and Parts Lists .......................................................... 20-23
CE Declaration of Conformity .................................................................. 24

4
Warnings
 The user shall ensure that the operating personnel are given the necessary
training.
 The operator shall always work in compliance with the operating
instructions.
 Clutch must be fully engaged before starting the winch operation.
 Do not disengage clutch under load.
 Stay out from under and away from raised loads.
 Stand clear of rope while pulling. Do not try to guide rope.
 It is forbidden to move loads above the rated capacity of the winch.
 Do not try to move fixed or obstructed loads.
 Do not use winch to lift, support, or otherwise transport people.
 A minimum of 2 wraps of rope around the drum barrel is necessary to
hold load.
 Avoid conditions where load shifts or jerks occur. Excessive “inching” shall
be avoided.
USER’S RESPONSIBILITY FOR CE COMPLIANCE
1. Use only a motor spool (open center) control valve per Hydraulic System
Requirements.
2. If a remote-operated winch control valve is used, refer to Hydraulic System
Requirements for Emergency Stop components to be installed.
3. Adjust system relief pressure per Hydraulic System Requirements.
4. Install the required hydraulic motor and “A” port motor control valve as shown in
the Hydraulic System Requirements.
5. Mount winch per Winch Mounting Instructions.
6. Install 16 mm (.630 inch), grade 1960 wire rope. Maximum rope length of 38 m
(125 ft) for three layers maximum. Attach rope to the drum per Rope Installation
Instructions. Hook must have a safety latch and a minimum breaking strength
of 225 kN.
Ra te d L ine P u ll 89 ,0 kN
20,000 (lb)
N ois e Le v el : 80 dB(A) at No Load
G e ar R e duc tio n 40:1
Layer of Rope 1 2 3
*Rated line pull per
la ye r
kN 8 9 ,0 73 ,8 6 3,2
(lb) 20,000 16,600 14,200
*R op e Ca p ac ity m* 10 23 38
Per Layer (ft)* 35 75 125
*L ine s
p
eed at MPM 5,4 6,3 7,2
114 LPM
(
30 GPM
)
(
FPM
)
18 21 24
* These specifications are based on recommended 16 mm (.63 in) 1960 grade
wire rope and a 244 cc (14.9 cu in)/Rev. motor.


5
TECHNIQUES OF OPERATION
The best way to get acquainted with how
your winch operates is to make test runs
before you actually use it. Plan your test in
advance. Remember, you hear your winch,
as well as see it operate. Get 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
rope, while pulling a load, is not a problem,
unless there is a rope 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 rope.
The Dow-Lok®clutch provides free spooling
and clutch engagement with the rope drum.
With the clutch disengaged, the rope can be
freespooled off the drum.
For winching in the load, the clutch must be
fully engaged with the drum.
The Dow-Lok®clutch is latched into either
the engaged, “IN” position, or the
disengaged “OUT” position, by a pin at the
bottom of the shifter handle which fits into
latching slots.
TO UNLATCH CLUTCH
Run winch in the reverse (reel out) direction
until the load is off the rope. Grasp handle
firmly, while pushing on the top of the
handle with the thumb for leverage, lift until
pin clears latching slots.
TO ENGAGE CLUTCH
Unlatch and pull handle toward “IN” position
as far as it will go. In order to attain full
engagement, internal elements of the clutch
must be aligned. This alignment will take
place when the rope drum or rope drum
shaft turns a maximum of 1/4 revolution.
The clutch will automatically spring into
engagement and pin will drop into “IN” slots
when this alignment takes place. Do not
attempt to pull a load unless pin is fully
into “IN” slots. Keep clear of spring
loaded handle during automatic
engagement.
TO DISENGAGE CLUTCH
Unlatch and push handle to “OUT” position
and fully insert pin into latching slots. Do not
disengage the clutch under load.
The Dow-Lok®air-shifter clutch provides
free spooling and clutch engagement with
the rope drum. With the clutch disengaged,
the rope can be freespooled off the drum.
For winching in the load the clutch must be
fully engaged with the drum.
TO ENGAGE CLUTCH
There must be a minimum of 0,5 m (1.5 ft)
of slack in the rope before attempting to
engage the clutch. This will allow the drum
to rotate a minimum of 1/4 turn allowing
engagement of the clutch before pulling the
load. With this slack in the rope, exhaust air
pressure from the air shift cylinder. Run the
winch in the “IN” direction until the clutch
starts to turn. Clutch must be fully engaged
before starting the winch operation.
TO DISENGAGE CLUTCH
Run winch in the “OUT” direction until there
is no load on the rope. Apply 4,8-6,2 bar
(70-90 psi) to the air shift cylinder to
disengage the clutch. Do not disengage
the clutch under load.
The Dow-Lok®low-profile shifter clutch
provides free spooling and clutch
engagement with the rope drum. With the
clutch disengaged, the rope can be
freespooled off the drum. For winching in the
load the clutch must be fully engaged with
the drum.

6
TO ENGAGE CLUTCH
Raise the handle so the notch clears the
bracket, and pull handle out as far as it will
go. The clutch will automatically spring into
engagement and latch when the clutch
aligns with the drum shaft. In order to attain
full engagement, internal elements of the
clutch MUST be aligned. This alignment will
take place when rope drum or rope drum
shaft turns a maximum of 1/4 revolution.
Do not attempt to pull a load unless notch in
shifter shaft is securely latched. Keep clear
of spring-loaded handle during automatic
engagement.
TO DISENGAGE CLUTCH
Raise handle so notch clears bracket.
Push handle in and latch the shaft notch
onto bracket. Do not disengage the clutch
under load.
WINCH 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
1. 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 in top of the
gear housing. Be sure that it is in good
operating condition so that hot oil gasses
may escape.
3. Lubricate rope with light oil.
B. MONTHLY
1. Lubricate the various grease fittings
located in the ends of rope drum shaft, end
bearing, clutch housing or clutch operating
linkage. Any good grade of moly-disulfide
containing grease is acceptable.
2. Check the action of the locking ring,
making sure it is spring loaded and free to
move fully against the rope drum in the
engaged position and that it is pulled fully
away from the rope drum and latched
when disengaged.
3. Check the winch mounting bolts. If any are
missing, replace them and securely tighten
any that are loose to recommended
torque. Make sure to use only grade
5 bolts or better.
4. Check the torque setting of the oil cooled
holding brake. Make any adjustments
required, following the procedure
described in ADJUSTING THE OIL
COOLED HOLDING BRAKE in the
Owner's Manual.
5. Inspect the rope. If the rope has become
frayed with broken strands, replace
immediately.
C. ANNUALLY
1. 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 minutes
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 E.P. 140 gear oil.
2. Inspect frame and surrounding structure
for cracks or deformation. Gear wear can
be estimated by rocking the drum back
and forth and if necessary drain oil and
remove cover for closer inspection.
3. Adjust the oil cooled holding brake. See
ADJUSTING THE OIL COOLED
HOLDING BRAKE on page 7.
WINCH MOUNTING
It is most important that this winch be
mounted securely so that the three major
sections (the clutch housing end, the rope
drum and the gear-housing end) are properly
aligned.
This H-89 Dow-Lok® series winch is furnished
with 13 x 76 x 102 mm (1/2 x 3 x 4 in) high-
strength steel angles.

7
ROPE INSTALLATION

The Ramsey Model H-89 Dow-Lok®winch has two tapered pockets cast into the drum.
One pocket is for installation with the wire rope wound over the drum. The other pocket is
for an underwound wire rope.
1. Slide the wire rope through narrow end of the pocket against the drum flange.
2. Wrap the wire rope around the anchor "puck" and pull the wire rope and anchor back
into the wide end of the pocket.
3. Use a soft hammer to drive the back side of the wire rope, firmly seating the wire rope
and anchor into the pocket.
The wire rope can easily be removed from the drum by driving the anchor out the wide end
of the pocket. While keeping tension on end of rope, carefully run the winch in the "reel-in"
direction spooling all the rope onto the rope drum. Take care to form neatly wrapped
layers.
INSERT ROPE AS SHOWN FOR
OVERWOUND APPLICATION
ROTATION
DIRECTION
TO REEL IN
ROPE ANCHOR
NOTE: ROTATION DIRECTION SHOWN WITH BRAKE
BALLS IN SLOT 2 ("A" ROTATION).

8
ADJUSTING THE OIL COOLED HOLDING
BRAKE
The oil cooled, fully adjustable, automatic holding
brake operates in the worm housing lubricant, all
parts being submerged in oil. The brake can be
adjusted as follows:
1. Loosen the lock nut on the adjusting screw.
2. Tighten the brake by turning the adjusting
screw clockwise. CAUTION: Only 1/4 turn is
usually required to adjust the brake.
Over-tightening can cause overheating, and
damage to the brake parts. Tighten the lock
nut after adjustment is completed.
If the brake does not respond to adjustment, then
a new leaf spring and brake disc is needed.
A torque wrench can be equipped with a special
adapter to fit the input shaft (worm) of the winch.
The adapter can be made by welding a nut to the
end of a piece of tubing as shown in the following
figure. After welding the cap and nut to the tubing,
slot the tubing, as shown. This will allow the
special adapter to slide over the keyway and will
then act as a large socket.
A torque wrench can the be used to apply the
proper torque. Turn the torque wrench so that the
drum turns in the spool out direction or lowering
direction. The torque rating for the brake on the
Model H-89 Dow-Lok® should be 68 to 75 Nm (50
to 55 ft- lb). If torque wrench does not show the
proper value as it turns, then the worm brake
adjusting bolt should be turned clockwise 1/4 turn.
Each time the adjusting bolt is turned, checked
the torque reading. Continue this procedure until
the proper torque reading is achieved, then
tighten the lock nut.
SERVICING OF THE OIL COOLED
HOLDING BRAKE
1. Remove the drain plug and drain the worm
gear oil from the worm housing.
2. Back off the lock nut, then the adjusting
screw, both two turns or more by turning them
counter-clockwise.
3. Remove the cover mounting screws.
4. Remove the cover along with coil spring and
leaf spring.
5. Remove the retainer plate, composition brake
disc, cam plate and balls. Note which slots
balls are in, #1 or #2. This will determine the
brake engagement direction.
6. Insert parts as follows:
a) Composition brake discs are 6,4 mm (1/4")
thick when new. Replace if thinner than 4,8
m (3/16”) or if surfaces are glazed or burnt.
b) Inspect the flat, ground surface of the
camplate and retainer plate for glazing,
warpage, or other damage. Glazing can be
removed by scraping carefully.
c) Inspect the leaf spring. It should be
bowed 1/8".
WORM HOLDING BRAKE
LEAF SPRING
COIL SPRING
BRAKE HOUSING
COVER
MOUNTING
SCREW
ADJUSTING
SCREW
DIAGRAM 1
BRAKE COVER
THREAD SEAL
JAM NUT
RETAINER PLATE
CAM PLATE
GASKET
PIN
A
BRAKE DISC
(LOOKING AT CAM
PLATE FROM WINCH)
VIEW A-A
1
2
1
2
COMPOSITION
A
BALL
HUB

9
RE-ASSEMBLING AND CHECKING THE HOLDING BRAKE
1. Press brake hub into place over worm shaft and key.
2. Assemble balls in appropriate slots of cam. See name and data tag for brake ball slot
position. Use stiff grease to hold balls into place and slide cam over end of worm. Be
sure that balls are secure, between cam slots and hub slots. Install brake disc.
3. Install retainer plate, smooth side toward brake disc.
4. Install the gasket on the cover with a small amount of grease or sealer.
5. The coil spring goes over the adjusting screw on the inside of the cover.
6. Install the notches of the leaf spring on the pins protruding through the cover.
The hollow side of the leaf spring goes toward the brake.
7. Install brake housing cover, making sure the protruding pins go through the leaf spring
and into the holes in the retainer plate.
8. Bolt cover into place with the mounting screws. Install drain plug and add 1,8 liters
(3-3/4 pints) of all purpose E.P. 140 oil.
9. Turn winch in the hoisting direction at least one turn of the input shaft.
10. Turn the adjusting screw in until it is finger tight.
TEST FOR PROPER HOLDING BRAKE ASSEMBLY
After the brake has been adjusted to the proper torque setting, disengage clutch. Start
vehicle engine and run winch in the reel in (pulling direction). Allow winch to run in this
direction for one minute.
Place your hand on the safety brake housing. If housing is not hot to the touch then run
winch in the reverse direction (rope out) for one minute. Brake housing should begin to
heat.
When these conditions exist, proper installation has been made. If heating becomes
noticeable when running the winch in forward rotation (pulling direction), the brake should
be again disassembled. When disassembled, place the brake balls in the alternate set of
slots in the cam plates, then carefully follow the instructions for re-assembling and
checking the brake.

10
ADJUSTMENT OF CLUTCH AIR SHIFTER
1. Place winch assembly back into
mounting frame and reattach using (8)
mounting bolts and lockwashers. Torque
mounting hardware to 393 Nm (290 ft-lb)
each. Make sure that gear housing and
clutch housing are not rubbing against
drum flanges.
2. Place air shifter assembly #1 over shifter
shaft aligning clevis over flats of shaft.
Secure clevis to shaft using clevis pin
#90 and cotter pin #89. Place shifter
shaft in the "ENGAGED" position. With
the air cylinder shaft fully retracted, push
shifter assembly toward the drum until all
play is taken out of the shifter shaft.
Secure shifter assembly to clutch
housing using (4) capscrews #82
(flanged hx. hd. serrated). Tighten
securely, but do not torque.
3. Hook up air 4,8-6,2 bar (70-90 psi) to
inlet port of air cylinder and disengage
clutch. Look into the opening in the
clutch housing and verify that the locking
ring and retainer plate are not making
contact. Locking ring and retainer plate
must not make contact. There must be a
clearance gap of 2,3 mm (.09 in) (max.)
between the locking ring and retainer
plate when the winch is fully disengaged.
If there is contact, the (4) capscrews #82
should be loosened and the plate pulled
away from the drum approximately 1,5
mm (.06 in). Tighten screws securely
and check action to assure needed
clearance. Repeat adjustment procedure
as needed to acquire needed gap. Shift
clutch 2 or 3 times to verify proper
shifting of clutch. After final adjustment,
torque (4) capscrews #82 to 24 Nm (18 ft
-lb) each. Attach cover #81 using (4)
capscrews #84.

11
CONDITIONS POSSIBLE CAUSE CORRECTION
CLUTCH INOPERATIVE OR
BINDS UP
1. Dry or rusted shaft. 1. Clean and lubricate.
LOAD DRIFTS 1. Holding brake has become
worn.
1. Replace brake disc (See
Servicing of the Oil
Cooled Safety Brake).
OIL LEAKS FROM WINCH 1. Seals damaged or
Worn.
1. Replace seal.
WINCH RUNS TOO SLOW 1. Low flow rate.
1. Check flow rate. Refer to
Hydraulic System
Requirements.
ROPE DRUM WILL NOT
FREESPOOL
1. Clutch not disengaged. 1. Check air pressure to clutch
cylinder 4,8 bar (70 psi) min.
required (See Adjustment of
Air Clutch Shifter).
ROPE BIRDNESTS WHEN
CLUTCH IS DISENGAGED
1. Drag brake disc worn. 1. Replace discs.
HYDRAULIC FLUID LEAKS
OUT HOLE IN MOTOR
ADAPTER
1. Hydraulic motor shaft
seal damaged.
1. Replace seal.
1. Bent yoke or linkage. 2. Replace yoke or shaft
assembly.
3. Debris in clutch. 3. Clean and lubricate.
4. Clutch not disengaging. 4. Adjust clutch air shifter
(See section under Main-
tenance).
2. Holding brake out of
adjustment.
2. Turn adjusting bolt clock-
wise 1/4 turn until load
does not drift
3. Incorrect hydraulic system. 3. Check hydraulic system. (See
Hydraulic System Require-
ments).
4. Load is greater than rated
capacity.
4. Reduce load.
2. Too much oil. 2. Drain excess oil. Refer to
Winch Maintenance.
3. Damaged Gasket. 3. Replace gasket.
2. Hydraulic motor worn 2. Replace motor.
2. Winch not mounted squarely,
causing end bearing to bind
drum.
2.Checkmounng(SeeWinch
Mounng).
TROUBLE SHOOTING GUIDE

12
HYDRAULIC SYSTEM REQUIREMENTS
1. Motor spool (open center) control valve.
2. Emergency Stop:
A. If winch is controlled by a direct-operated manual valve, that valve serves as the
E-stop.
B. If a remote operated control valve is used, a solenoid-operated hydraulic dump
valve, normally open to tank, and an emergency stop switch (to open the dump
valve) is required. The E-stop switch is to be normally closed and have a red,
resettable push button actuator with a yellow background. The E-stop switch
must be easily accessible to the operator.
3. “A” port motor control valve rated for a maximum flow of 114 LPM (30 GPM).
4. Hydraulic motor with a volume of 244 cc (14.9 cu in)/rev.
5. Relief valve set to 151,7 bar (2200 psi) which is the rated capacity limiter.
6. Flow rate of 114 LPM (30 GPM) maximum.
7. Hydraulic fluid with a viscosity between 20-43 cSt (100-200 SUS). Maximum operating
temperature 85C (180F). Cleanliness level of ISO 17-14 or better.
Note: Some models are sold without the hydraulic motor and “A” port motor control valve.
It is the User’s responsibility to meet the following meet the Hydraulic System
Requirements.
(RATED CAPACITY LIMITER)
151,7 bar (2,200 PSI)
114 LPM (30 GPM)
33 mm (1.31 in) I.D. MINIMUM
I.D. MINIMUM
22 mm (.88 in)
PUMP
LOW PRESSURE LINE
HIGH PRESSURE LINE
RATED LOAD:
PRESSURE AT
MAX. FLOW &
(MOTOR SPOOL)
4 WAY VALVE
3 POSITION SYSTEM RELIEF
PROVIDED BY USER
DUMP VALVE
*
*E-STOP SWITCH
REQUIRED ONLY IF REMOTE-OPERATED CONTROL VALVE IS USED. SEE 2B
*IN HYDRAULIC SYSTEMS REQUIREMENTS. NOT REQUIRED FOR A
DIRECT-OPERATED MANUAL VALVE.
A PORT
MOTOR CONTROL VALVE
TYPICAL HYDRAULIC LAYOUT
WINCH MOTOR
HYDRAULIC
151,7 bar (2,200 PSI)
12/28/2013

13
LINE PULL-FIRST LAYER, kN (LB)
WORKING PRESSURE, bar (PSI) AT 114 LPM (30 GPM)
0
(6,000)
20769 138
LINE SPEED-FIRST LAYER, MPM (FPM)
FLOW, LPM (GPM)
(5)
0
038 76 114
(16,000)
(8,000)
(18,000)
(10,000)
(20,000)
(12,000)
(14,000)
(10)
(15)
(20)
89,0
80,1
71,2
62,3
53,4
44,5
35,6
26,7
6,1
4,6
3,1
1,5
(1000) (2000) (3000) (30)(20)(10)
PERFORMANCE CHARTS
Refer to the performance charts below to properly match your hydraulic system to the
winch performance. The charts consist of: (1) Line Pull first layer kN (lb) vs. Working
Pressure bar (psi). (2) Line Speed, first layer MPM (FPM) vs. flow LPM (GPM).

14
INSTRUCTIONS FOR OVERHAUL OF RAMSEY
MODEL H-89 DOW-LOK®
DIS-ASSEMBLY
Refer to parts list and parts drawing pages for actual
item numbers and corresponding part numbers.
FIGURE 1
Drain oil from gear housing by removing
pipe plug #88 from gear housing. Shift clutch
into engaged “IN” position. If equipped with
air shifter, remove air shifter cover #43,
cotter pin #75, and clevis pin #76. Remove
air shifter sub-assembly #5. Remove frame
angles #7 & #8 from winch assembly.
FIGURE 2
Remove two capscrews #53 from clutch
housing #21 and unlatch shifter assembly #34.
Remove clutch housing from end of drum shaft.
Press in on retainer plate #93, to relieve the
spring tension and remove the retainer ring #96.
Remove four cap screws #44, retainer plate
#93, springs #99 and spacer #35.
FIGURE 3
Slide the locking ring #14 from the clutch.
NOTE: The locking ring cannot be removed
unless the clutch is engaged, with dowel pins
#90 seated in the shaft keyways.
Rotate the drum so the eight balls #39 and four
dowel pins #90 can be removed.
If necessary, the clutch #13 may be
disassembled from the drum by removing eight
capscrews #50. Slide drum #18 from drum
shaft.
FIGURE1
FIGURE2
FIGURE3

15
FIGURE 4
Remove motor #85 from adapter plate #29 by
removing capscrews #59. Remove adapter
plate and coupling #3 from adapter #6 by
unscrewing eight capscrews #56.
Remove key #26 from worm shaft. Unscrew
six capscrews #58 and remove adapter from
gear housing. Replace adapter seal #94 and
gasket #78.
Drag brake #17, spacer #103 and springs #98 should be
examined and replaced if necessary.
FIGURE 5
Remove brake housing #20 from gear housing
by unscrewing six #57 capscrews. Refer to
page 7, SERVICING OIL COOLED HOLDING BRAKE.
Remove key #25 from worm. Remove worm
#36 and bearings #40 from gear housing. Use
a soft hammer to gently tap input end of worm, driving
worm and bearing from gear housing. Once worm has been
removed from housing, bearing can be pressed from end of
worm. Check for signs of wear or damage to worm #36
and bearings #40. Replace if necessary.
FIGURE 6
Remove gear-housing cover #16 from gear
housing #22 by unscrewing eight capscrews
#47. Thread two of the capscrews into the two
tapped holes of cover and tighten. This will pull
the cover loose from gear housing. Remove cover gasket
#80 and pull shaft #32, with gear #19 and spacer #101
attached, from gear housing.
FIGURE 7
If necessary, replace gear. Check lube fittings #84 and
reducer #87 for damage and replace if necessary.
87
87
84
84
32
70
19 52
24
FIGURE 7
19
80
32
22
101
47
16
FIGURE 6

16
FIGURE 8
If shaft and/or gear is damaged, replace as
follows:
a. Tap keys #27 into short keyways of drum shaft #32.
b. Press shaft #32 and keys through gear hub #19 until
end of keys on long end of shaft are flush with gear.
FIGURE 9
Check gear housing bushing #10 and o-ring #86 for signs
of wear. Replace if necessary by pressing old bushing from
gear housing #22. Press new bushing into place and insert
new o-ring #86 into groove inside of bushing.
FIGURE 10
Check drum bushings #41 & #42 for signs of wear.
Replace if necessary by pressing old bushings from drum
#18. Press bushing #41 into bore in drum until flange is
seated against bottom of counterbore. Press bushing #42
into opposite bore on drum until end of bushing extends .50"
from end of drum.
FIGURE 11
Check end bearing bushing #42 for signs of wear. If
necessary, remove old bushing and press new bushing into
place.
FIGURE 12
Check cover bushing #10 and o-ring #86 for signs of
wear. Replace if necessary by pressing old bushing from
gear housing cover #16. Press new bushing into place and
insert new oring #86 into groove inside of bushing.
27
32
27
19
FIGURE 8

17
FIGURE 13
Slide spacer #101 over long end of shaft and place
against gear hub. Apply grease to end of shaft,
opposite gear. Apply grease to bushing in gear housing
#22. Place greased end of shaft through bushing in
gear housing #22. Place gasket #80 onto gear
housing cover #16. Apply grease to gear end of shaft
andcover bushing. Place cover onto shaft and secure
to housing with eight #47 capscrews. Tighten
capscrews to 53 Nm (39 ft-lb) each.
FIGURE 14
Press bearing #40 onto worm #36. NOTE: Be sure that
thick shoulder of bearings outer race (side with
manufacturer's name and part number) is out, away
from worm threads. Press bearing and worm into gear
housing. Slip gasket #78 onto brake housing #20. Use
six capscrews #57 to secure brake housing
to gear housing. Tighten capscrews to 61 Nm (45 ft-lb)
each. Place key #25 into keyway of worm #36. Refer
to page 8 for reassembly and checking of worm brake.
FIGURE 15
Press bearing #40 onto worm and into housing. NOTE:
Be sure that thick shoulder of bearings outer race (side
with manufacturer's name and part number) is out,
away from worm threads. Attach adapter #6 to gear
housing using six capscrews #58. Tighten
capscrews to 61 Nm (45 ft-lb) each. Insert key #26
into keyway of worm shaft. Slide coupling #3 over end
of worm shaft. Attach adapter plate #29 to adapter
using eight capscrews #56. Tighten capscrews to 28
Nm (21 ft-lb) each. Place motor shaft, with key in
keyway, into coupling. Secure motor #85 to adapter,
using two capscrews #59. Tighten capscrews to 138
Nm (102 ft-lb) each.
FIGURE 16
Place winch with gear housing cover down on work
bench. Drum shaft should be in vertical position. Set
springs #98 into pockets of gear housing with drag
brakes #17 on top of disc #103 and springs. Apply
grease to shaft and drum bushings. Slide drum
assembly #18 onto drum shaft as shown.
101
22
32 16
80
19
47
FIGURE 13

18
FIGURE 17
Place clutch #13 over end of drum shaft. Align the
clutch over the pilot bushing in drum. Install the
eight capscrews #50 and torque the capscrews to
138 Nm (102 ft-lb) to securely seat the clutch to
the drum. Rotate the drum to align the clutch slots
with the shaft keyways. Lightly grease four dowel
pins #90 and eight balls #39. Use molybdenum
disulfide or graphite bearing grease. Insert the four
dowel pins #90 and eight balls #39. In the engaged
position the balls are nearly flush with the clutch.
Lightly grease the internal and external groove and
bore in locking ring #14 and clutch #13.
Slide locking ring onto the clutch. When fully en-
gaged, the locking ring touches the clutch flange
and there is 18 to 18,5 mm (.71 to .73 in) between
the end of the locking ring and the end of the clutch.
FIGURE 18
Place four springs #99 over four roll pins on retainer
plate #93. Install spacer #35 and retainer
plate and secure to clutch using four capscrews
#44. Tighten capscrews to 13 Nm (9.7 ft-lb) each.
Firmly seat the retainer ring #96 into drum shaft
groove. Set the shifter assembly so that the screw
heads engage the external groove in the locking ring
#14. Push the clutch housing #21 onto the drum
shaft and latch the shifter assembly in the engaged
"IN" position. Insert the two capscrews #53.
FIGURE 19
Attach mounting angles #7 & #8 to winch assem-
bly. Use capscrews #55 & #56 and lockwashers
#73. Tighten capscrews to 393 Nm (290 ft-lb)
each. Insert plug #88 into hole in bottom of gear
housing. Remove plugs #81 & 87 from top of
housing. Pour 1.77 liters (3-3/4 pints) of E.P. 140
oil into hole and replace plugs. Attach air shifter as-
sembly, but do not torque prior to adjustment (refer
to page 9). Attach clevis #33 to shifter shaft #34
with clevis pin #76 and cotter pin #75. Attach cov-
er #43.