Ramsey Winch HD-P8000 User Manual

Page 9

Remove seal (item #37) from gear housing end bearing (item #9). Loosen nut
(item #20) and remove nylon setscrew (item #17). Remove ring gear from
gear housing end bearing, if necessary. Remove bushing (item #12) 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 #26),
teeth of planet gears in drum (item #1), and to bushing (item #12) in gear
housing end bearing. Apply a small amount of grease to base of bushing (item
#13) on motor end bearing. Apply grease to teeth of output sun gear (item #7) and input shaft (item #10).

Place end of shaft with output sun gear on it into drum (item #2). 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 #8) to drum assembly and use tie plates (items #11) and capscrews (items #15) 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 #19) and jam nut, 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 rev-
olution) with clutch shifter at the DISENGAGED
position. Securely tighten jam nut while holding
the handle. Tighten setscrew (item #19) secure-
ly. Re-check clutch operation as described on
page 5.

AIR CYLINDER SHIFTER ASSEMBLY

Loosen set screw (item #19) to remove shifter
assembly (item #3). To reinstall, place 1 or 2
shims (items #41) over plunger and thread
shifter assembly into gear end housing. Add or
remove shims to orient ports for pneumatic con-
nections. Ports should point down (below hori-
zontal). Tighten setscrew. Check for clutch oper-
ation as described on page 5.

If the light assembly (item #2) or light switch
(item #45) needs to be replaced, refer to the
schematic on page 12 for electrical connections
and disassemble and reassemble as shown.

JAM NUT

PLUNGER

AIR-CYLINDER

CLUTCH SHIFTER

MANUAL CLUTCH
SHIFTER

MANUAL CLUTCH ADJUSTMENT

HANDLE (HORIZONTAL)

CYLINDER

LIGHT SWITCH

LIGHT ASSEMBLY