Ramsey Winch HD-P10000 Installation and user guide

TABLE OF CONTENTS
INTRODUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HYDRAULIC SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TYPICAL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OVERHAUL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2
PARTS LIST AND PARTS DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16
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.

PLEASE READ THIS MANUAL CAREFULLY
This manual contains useful ideas for 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 "WARNING" 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.
WARNINGS:
A MOTOR SPOOL (OPEN CENTER) DIRECTIONAL CONTROL VALVE IS REQUIRED FOR BRAKE OPERATION.
CLUTCH MUST BE FULLY ENGAGED BEFORE STARTING THE WINCH.
DO NOT DISENGAGE CLUTCH UNDER LOAD.
DO NOT LEAVE CLUTCH ENGAGED WHEN WINCH IS NOT IN USE.
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 PERSONNEL.
A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD. CABLE CLAMP
(SETSCREW) IS NOT DESIGNED TO HOLD LOAD.
IN CAR CARRIER APPLICATIONS, AFTER PULLING VEHICLE ON CARRIER, BE SURE TO SECURE VEHICLE TO CARRIER
BED. DO NOT MAINTAIN LOAD ON WINCH CABLE WHILE TRANSPORTING VEHICLE. DO NOT USE WINCH AS A TIEDOWN.
WHEN PULLING A HEAVY LOAD PLACE A BLANKET, JACKET, OR TARPAULIN OVER THE CABLE FIVE OR SIX FEET FROM
THE HOOK.
AVOID CONDITIONS WHERE LOAD SHIFTS OR JERKS OCCUR, AS THEY MAY INDICATE A DANGEROUS SITUATION.
3
Rated Line Pull (lbs.)
………………………………………
10,000
(Kg.)
………………………………………
4,545
Gear Reduction 5.1:1
HD-P10000 STD. …….. 87 lbs. (39.5 Kg)
HD-P10000 "Y" ……….. 82 lbs. (37.2 Kg)
1234
lbs. 10,000 8,300 7,100 6,200
Kg. 4,530 3,760 3,220 2,810
ft. 205080115
m 6 15 24 35
ft. 15305575
m491622
FPM32384451
MPM 9.8 11.6 13.4 15.5
………………………………………………
Weight (without cable)
* These specifications are based on recommended wire rope of
7/16" (11mm) EIPS cable and a 24.9 cu.in./Rev. motor.
LAYER OF CABLE
*Rated line pull
per layer
HD-P10000
(STD. DRUM)
* Line Speed (at
15 GPM)
HD-P10000 ("Y"
DRUM)
* Cable Capacity per Layer

WINCH MOUNTING
ESSENTIAL MOUNTING INSTRUCTIONS TO MAINTAIN ALIGNMENT OF PLANETARY WINCH COMPONENTS:
It is most important that this winch be mounted securely so
that the three major sections (the motor end, the cable drum,
and the gear housing end) are properly aligned. Excessive
bushing wear and difficulty in freespooling are usually symp-
toms of misalignment.
In the as-installed condition, if the winch is mid-mounted,
then at least one tie-plate must be attached to the mounting
feet at the bottom of the winch to maintain alignment. If the
winch is foot mounted then at least one tie-plate must remain
mounted at midpoint of winch to maintain alignment. It is
always preferred to used BOTH tie-plates in the final installed
configuration.
Angle Mounting Kit, P/N 251006 (for Std. Drum) or 251007
(for “Y” drum), is recommended for maximum ease in
mounting the winch. The angle kit will allow the winch to be
mounted in upright or midmount applications and will meet
the criteria of serving as a solid and true mounting surface.
When mounting the winch with other than the recommended
Ramsey Angle Kit, the mounting hole patterns described in
the Dimensional drawings on pages 14-15 should be used.
The mounting surface must be flat within .015 inch and suffi-
ciently stiff to resist flexing. If a steel plate is used for foot
mounting, it should be .750 inch thick. For this mounting application eight (8) 1/2-13NC x 1-1/2” long grade 5 capscrews with lockwashers
will be needed to mount winch. Capscrews should be tightened to 85 ft-lb (115 Nm) torque.
NOTE: If angles or a steel plate are used in mounting winch, tie-plates provided with winch are to be attached to the remaining mounting
pads, whether they be side or foot.
CABLE INSTALLATION
An “A” or “B” decal on the clutch end bearing indicates the spooling direction of the cable. Also, a letter “A” or “B” is stamped in the end
bearing on the clutch end indicating rotation direction. If the decal is damaged or unreadable, contact Customer Service for additional
instructions to determine proper direction. To reverse the rotation direction, exchange positions of the cartridge and plug shown at
right.
1. Unwind cable by rolling it out along the
ground to prevent kinking. Securely wrap
end of cable, 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 the 3/8-16NC
x 1/2” long hex socket drive setscrew
(included with drum assembly item #1) to
secure cable to drum.
3. Carefully run winch in the "reel-in" direc-
tion. 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 opera-
tion. Disengage clutch and pull on cable at a
walking speed. If cable “birdnests”, loosen
jam nut (item #20) and turn nylon setscrew
(item #17) clockwise to increase drag on
drum. If cable pull is excessive, loosen nylon
setscrew by turning counterclockwise. Tighten jam nut when proper setting is obtained.
CAUTION: OVER-TIGHTENING OF JAM NUT MAY STRIP NYLON SETSCREW.
MOTOR END CABLE DRUM
GEAR HOUSING END
TIEPLATE AT SIDE LOCATION
TIEPLATE AT FOOT (BASE) LOCATION
FOOT MOUNT
MID MOUNT
CAUTION: If longer bolts (minimum grade 5) are substituted to mount winch or to
mount a roller guide at the side mount pads, bolt length must be such as to allow a
minimum of .50 inch thread length engagement in the tapped holes in side of each
end bearing. Use of excessive length bolts will damage the winch and prevent
freespool of the drum. Torque bolts to 55 ft-lbs. (75 Nm).
SETSCREW
"A" ROTATION
DIRECTION
"B" ROTATION
DIRECTION
INSERT CABLE AS SHOWN FOR "B" ROTATION
OVERWOUND APPLICATION.
(UNDERWOUND APPLICATION REQUIRES CABLE TO
COME UNDER DRUM FROM OPPOSITE DIRECTION
AND INSERTED IN THIS SAME CABLE POCKET.)
INSERT CABLE AS SHOWN FOR "A" ROTATION
OVERWOUND APPLICATION.
(UNDERWOUND APPLICATION REQUIRES CABLE TO
COME UNDER DRUM FROM OPPOSITE DIRECTION
AND INSERTED IN THIS SAME CABLE POCKET.)
20
17
4

5
MAINTENANCE
1. Inspect the cable for damage and lubricate frequently. If the cable becomes frayed with broken strands, replace immediately. Cable and
hook assembly (100’ long cable) P/N 524118 (“Y” drum) or (150’ long cable) P/N 524119 (STD drum) may be purchased from a
Ramsey distributor.
2. Check that the clutch is fully engaging. See OPERATION instructions, above, for the appropriate clutch shifter. FOR MANUAL CLUTCH
ONLY: Monthly, disengage clutch, put several drops of oil on the clutch handle shaft and work clutch handle IN and OUT several times
to lubricate inside the shifter assembly.
3. Check to see that the drum cable does not overrun (“birdnest”) when freespooling. Refer to page 4 if it does.
4. Replace drum bushings and seals if seals begin to seep grease. Refer to the Overhaul Instructions, pages 8-10. Add additional lubri-
cant, Mobilith SHC 007, to gears and drum bearings if required.
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. Avoid conditions where load shifts or jerks occur, as they may indicate a dangerous situation.
The uneven spooling of cable, while pulling the load, is not a problem, unless there is a cable pileup on one end of the 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.
When pulling a heavy load, place a blanket, jacket, and tarpaulin over the cable about five or six feet behind the hook. In the event of a bro-
ken cable, this will slow the snap back of the cable and could prevent serious injury.
The winch clutch allows rapid unspooling of the cable, from the cable drum, for hooking onto the load. The clutch is operated by the clutch
shifter lever or air shifter.
WARNING: DO NOT DISENGAGE CLUTCH UNDER LOAD!
MANUAL CLUTCH SHIFTER (Refer to dimensional drawing page 11):
TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until the load is off the cable. Pull handle out and rotate 90°. With
handle in the “DISENGAGED” position, cable may now be free-spooled from the drum.
TO ENGAGE CLUTCH: Pull handle out, rotate 90° and release handle. Run the winch in reverse until the clutch handle snaps fully into the
“ENGAGED” position. DO NOT attempt to pull a load unless the handle is fully at the “ENGAGED” position. If manual shift indicator light is
present, the green light is lit when clutch is fully “ENGAGED”. DO NOT attempt to pull a load unless the green light is lit. To install light to the
vehicle electrical system refer to the Electrical Schematic on page 12.
AIR CYLINDER CLUTCH SHIFTER (Refer to the dimensional drawing page 12):
TO DISENGAGE CLUTCH: Run the winch in the reverse (reel out) direction until load is off the cable. Apply air pressure to the .125-27 NPT
port: 80 PSI (min.)-150 PSI (max.). CAUTION: PRESSURE MUST NOT EXCEED 150 PSI.
TO ENGAGE CLUTCH: Remove air pressure from the cylinder (a return spring engages the plunger). Run winch in reverse until the clutch
engagement indicator light (green light) is lit. To install light to the vehicle electrical system refer to the Electrical Schematic on page 12.
(REEL IN) RAISE INLET
"A" ROTATION "B" ROTATION
CABLE DRUM
ROTATION DIRECTION
CABLE DRUM
ROTATION DIRECTION
CARTRIDGE
POSITION CARTRIDGE
POSITION
PLUG
POSITION

HYDRAULIC SYSTEM REQUIREMENTS
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 (lb.) vs. Working Pressure (PSI)
(2) Line Speed, first layer (FPM) vs. flow (GPM)
SYSTEM REQUIREMENTS
MOTOR SPOOL (OPEN CENTER) CONTROL VALVE REQUIRED
2100 PSI RELIEF VALVE SETTING
15 GPM FLOW RATE
DO NOT EXCEED 20 GPM--MOTOR AND WINCH MAY BE DAMAGED
10 MICRON NOMINAL FILTRATION
SYSTEM
RELIEF
3 POSITION
4 WAY VALVE
(MOTOR SPOOL)
MAX. FLOW &
PRESSURE AT
RATED LOAD:
15 GPM
2100 PSI
HIGH PRESSURE LINE
(.50 I.D. MINIMUM) LOW PRESSURE LINE
(.75 I.D. MINIMUM)
PORT CONTROL
B
TYPICAL LAYOUT
WITH BRAKE RELEASE SHUTTLE
MOTOR
BRAKE
PORT
A
WORKING PRESSURE (PSI) AT 15 GPM FLOW (GPM)
LINE PULL-FIRST LAYER (LB)
LINE SPEED-FIRST LAYER (FPM)
051015
0
5
10
15
0
0
1000
2000
3000
4000
5000
6000
7000
8000
1000 2000 2500
BASED ON 24.9 CU. IN. MOTOR
1500500
PERFORMANCE CHARTS
9000
10000
6

TROUBLESHOOTING GUIDE
CONDITIONS POSSIBLE CAUSE CORRECTION/ACTION
DRUM WILL NOT ROTATE
AT NO LOAD
Winch not mounted squarely, causing end bearing
to bind up
Check mounting. Refer to Winch Mounting, page 2.
Gears damaged Inspect and replace damaged gears
DRUM WILL NOT ROTATE
UNDER LOAD
Winch not mounted squarely, causing end bearing
to bind up
Check mounting. Refer to Winch Mounting, page 2.
Load greater than rated capacity of winch Refer to Specifications page 1 for line pull rating.
Low hydraulic system pressure Check pressure. Refer to Hydraulic Systems per-
formance charts page 4.
WINCH RUNS TOO SLOW Low hydraulic system flow rate Check flow rate. Refer to Systerm Requirements and
Typical Layout page 4.
Motor worn out Replace motor
DRUM WILL NOT
FREESPOOL
Clutch not disengaged. Check Adjustment of Manual
Shifter, page 10.
Check Operation, page 5.
Winch not mounted squarely, causing end bearing
to bind up
Check mounting. Refer to Winch Mounting, page 2.
Side mounted bolts too long, causing binding of ring
gear (Item #15, page 16).
Check bolt length. Bolt thread MUST NOT engage
threaded holes in sides of end bearing more than the
.50 inch thread depth in the end bearing.
BRAKE WILL NOT HOLD Incorrect directional control valve (cylinder spool-
closed center)
Use only a motor spool (open center) control valve.
LOAD DRIFTS Excessive Backpressure (100 PSI Max.) Check for restrictions in hydraulic system. Refer to
System Requirements and Typical Layout page 4.
CABLE BIRDNESTS WHEN
CLUTCH IS DISENGAGED
Drag screw improperly adjusted Adjust nylon drag screw. Refer to Cable Installation,
page 3.
EXCESSIVE NOISE Hydraulic system flow too high Check flow rate. Refer to Typical Layout page 4.
Drum in bind, winch not mounted squarely Check mounting. Refer to Winch Mounting, page 2.
DRUM CHATTERS IN
“REEL IN” DIRECTION
Low hydraulic system flow rate Check flow rate. Refer to Typical Layout page 4.
Low hydraulic system relief pressure setting Check relief valve setting.
OIL LEAKS FROM
BREATHER VENT UNDER
MOTOR END BEARING
Damaged brake o-rings, backup rings, or sealing
surfaces
Disassemble brake and inspect. See Overhaul
Instructions, pg. 8.
7

14
37
10
41
47
8
11
1
12
16
12
16
5
4
35
33
7
31 36
32
34
6
42
49
INSTRUCTIONS FOR OVERHAUL HD-P10000 SERIES WINCH
Take note of mounting configurations for proper mounting of parts during re-assembly. Replace all gaskets, o-rings,
and seals during re-assembly.
Disconnect tube (item #44) from elbow fittings (items
#26) on bottom of end bearing and counterbalance valve
(item #45). Remove motor (item #30) from end bearing
by slowly unscrewing capscrews (items #19). CAUTION:
MOTOR IS UNDER SPRING PRESSURE.
Check breather vent (item #48). Make sure it is not
clogged. If oil is leaking from vent, check brake o-rings,
backup rings, and sealing surfaces (see page 8).
Remove springs (items #43) from pockets and inspect for
damage.
Replace gasket (item #28).
Remove coupling (item #25) from end bearing. Examine
coupling for signs of wear, replace if necessary. If necessary, re-
move counterbalance valve from motor by removing capscrews
(items #15).
Remove retaining rings (items #42 and 49) with screwdriver.
Remove brake parts from end bearing. NOTE POSITION OF
O-RINGS AND BACKUP RINGS BEFORE REMOVAL. Examine
brake discs (items #5) and stators (items #4) for signs of
wear, and replace if necessary.
Examine o-rings (items #31 and 32) and backup rings
(items #34 and 36) in brake piston (item #6), as well as oring
(item #33) and backup ring (item #35) in backup brake
piston (item #7) for signs of wear. Remove o-rings and
backup rings from grooves in brake piston or backup brake
piston and replace if necessary.
Remove tie plates (items #12) from end bearings by
unscrewing capscrews (items #16). Slide motor end
bearing (item #10) and drum (item #1) from gear housing
end bearing.
Remove input shaft (item #11) from end bearing. Inspect
shaft and and output sun gear (item #8) for damage and
replace if necessary. To remove the output sun gear,
remove the snap rings (items #41) and thrust washer
(item #47) and pull off the end of the shaft.
Remove bushing (item #14) and o-ring (item #37) from
motor end bearing. Place new, well-oiled o-ring into
groove inside of end bearing and press new bushing onto
end bearing.
8
43
44
26
45 23
15
26
25
28
30
24
19
48

Remove seal (item #40) from gear housing end bearing (item #9).
Loosen nut (item #22) and remove nylon setscrew (item #18). Remove
ring gear from gear housing end bearing, if necessary. Remove bushing
(item #13) from end bearing.
Press new bushing into end bearing. Install ring gear, then nylon setscrew
and nut. Ring gear must be fully seated in end bearing and slot in ring
gear MUST NOT be aligned with clutch shifter hole. Install new seal in end
bearing, with sharp edge of seal outward.
Generously apply grease (MOBILITH SHC 007) to teeth of ring gear (item
#29), teeth of planet gears in drum (item #1), and to bushing (item
#13) in gear housing end bearing. Apply a small amount of grease to
base of bushing (item #14) on motor end bearing. Apply grease to teeth
of output sun gear (item #8) and input shaft (item #11).
Place end of shaft with output sun gear on it into drum. Rotate shaft to
engage planet gears with output sun gear. Place Gear End Bearing on Drum and engage planet gears with ring gear.
Assemble motor end bearing (item #10) to drum assembly and use tie plates (items #12) and capscrews (items #16) to hold
both end bearings together. Tighten capscrews to 55 ft-lbs (75 Nm).
If necessary, remove and replace the shifter assembly (manual, item #2, or air-cylinder, item #3), as follows:
MANUAL CLUTCH SHIFTER ASSEMBLY
Loosen setscrew (item #20) and jam nut on shifter assembly, then unscrew shifter assembly (item #2). Be sure slot in ring
gear is not aligned with clutch shifter hole. Rotate drum, if necessary, to ensure hole and slot are not aligned.
Reinstall shifter assembly with plunger, jam nut, and handle positioned in gear housing as shown below. Thread assembly (with
handle engaged in cylinder slot) into the gear housing. Pull drum toward the gear end bearing housing to remove play. Hold
drum in position and continue threading the shifter assembly in until the gap between the end of the handle and cylinder is
7/16 +0 -1/16 inch and handle is in the horizontal position (see below). Note: This gap will vary with drum endplay. With the
drum pulled against the motor end housing, the gap should be 3/8 inch.
Lightly tighten jam nut. Rotate drum until handle snaps fully into the engaged position. Pull handle out and rotate 90°. Verify that
drum can be rotated freely (at least one full revolution) with clutch shifter at the DISENGAGED position. Securely tighten jam nut
while holding the handle. Tighten setscrew (item #20) securely. Re-check clutch operation as described on page 5.
AIR CYLINDER SHIFTER ASSEMBLY
Loosen set screw (item #20) to remove shifter assembly (item
#3). To reinstall, place 1 or 2 shims (items #44) over plunger
and thread shifter assembly into gear end housing. Add or
remove shims to orient ports for pneumatic connections. Ports
should point down (below horizontal). Tighten setscrew. Check
for clutch operation as described on page 5.
If the light assembly (item #2) or light switch (item #48)
needs to be replaced, refer to the schematic on page 15 for
electrical connections and disassemble and reassemble as
shown below.
29
40
22
18
13 9
9
20
9
42
48
LIGHT SWITCH
LIGHT ASSEMBLY
CYLINDER
23
4
41
2
3
44
21
2
JAM NUT
PLUNGER
AIR-CYLINDER
CLUTCH SHIFTER
MANUAL CLUTCH
SHIFTER
MANUAL CLUTCH ADJUSTMENT
HANDLE (HORIZONTAL)

MOTOR SIDE
36
31
3533
32
34
7
6SECTION A-A
A
A
5
4
35
33
7
31 36
32
34
6
42
49
38
43
45 23
15
25
28
30
24
19
26
26
44
48
Set winch with 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 crosssection A-A below.
Piston, backup piston, brake discs and stators must be clean and free of grease and oil.
Insert brake discs (item #5) and stators (item #4) into gear end alternating, with stators first and last.
Insert backup brake piston (item #7) into motor end and insert brake piston (item #6) into it. Apply even pressure on piston
when installing.
Install retaining rings (items #42 and 49) into grooves in motor end housing.
Insert springs (item #43) into pockets in back of brake piston.
Install roll pin (item #38) into new motor coupling below bottom of spline teeth. Insert motor coupling (item #25),
engaging it with the discs and the input shaft.
Place gasket (item #28) on mounting surface of motor (item #30). Slide motor shaft into coupling. Attach motor to motor end
bearing housing using (2) capscrews (item #19) and (2) lockwashers (item #24). Evenly tighten to 49 ft-lbs. (66 Nm) torque.
Install the counterbalance valve (item #45) to the motor using (4) capscrews (item #15) and (4) lockwashers (item #23).
Tighten to 17 ft-lbs (23 Nm).
Securely connect fittings (item #26) to motor
end housing and counterbalance valve, and
connect tube assembly (item #44) to fittings.
Apply at least 550 PSI hydraulic system pressure
to brake and verify that brake releases
(winch drum will rotate).
10