Ramsey 256103 User Manual

STEP 1

Remove winch assembly from mounting angle or
frame. Remove clutch housing assembly from winch.
Remove rubber plug and setscrew from clutch hous­ing, discard rubber plug and setscrew. Drive pin from
handle and remove handle, spring and shifter shaft
from clutch housing. Discard spring, shifter shaft,
handle and pin.

STEP 2
Add holes to existing clutch housing:

Use the air cylinder as a guide for hole layout loca­tions. This is accomplished by aligning the air cylin­der (item #6) to the thru hole inside the clutch hous­ing. Lower clutch housing (open end first) over the
air cylinder shaft. The end of the air cylinder shaft
should protrude through the closed end of the clutch
housing. Take template from page 5 and cut-out 1/2”
dia. hole. Lay template over clutch housing and air
cylinder shaft. Align the edges with the mounting
pads and clutch housing. Use a center punch at the
center locations of the four 5/32” (.156) diameter
holes to mark housing. Remove template and air
cylinder. Use 5/32” (.156) diameter drill to drill thru
housing at (4) center punched locations.

STEP 3
Air cylinder Sub-up:

Apply thread sealant to threads of elbow fitting (item
#5) and threads of breather vent (item #11). Attach
elbow fitting (item #5) to port at shaft end of air cylin­der (item #6), pay attention to position the end of the
elbow fitting 180 degrees from the shaft, as shown.
Attach the breather vent (item #11) to the port at the
other end of the air cylinder.

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912585-0905-B

Installation Instructions for Air Shifter Kit #256103

STEP 4
Air cylinder to clutch housing sub-up:

Insert shaft of air cylinder through hole in shim (item #13),
then insert shaft of air cylinder (item #6) into hole of clutch
housing, as shown. Line up holes of air cylinder and shim
to holes drilled previously in clutch housing. Pay attention
to allow flat portion of shim to be at the top to provide
clearance between the letters on the clutch housing and
the air cylinder. Install the bottom 2 socket hd. capscrews
(item #2) with lockwashers (item #4) from inside of the
clutch housing and torque to 28 in.lbs. each, so that the
shim will remain tight against the air cylinder and not allow
it to pivot. Install the top 2 remaining capscrews and lock­washers and torque to 28 in.lbs. each. Place spring (item
#14) over shaft and place yoke (item #1) over threads at
end of air cylinder shaft. While holding the air cylinder
shaft at the wrench flats tighten down the flex locking nut
(item #3), torque to 170 in.lbs.

STEP 5
Clutch housing assembly to winch:

Apply grease to keys and end of shaft. Place clutch hous­ing over end of drum shaft. Pull jaw clutch upward, toward
clutch housing, enough to allow yoke, in clutch housing, to
fit properly in groove around jaw clutch. Air may have to
be applied to force housing down onto drum. Reinstall
winch into mounting frame.

STEP 6
Verify clutch ENGAGED and DISENGAGED positions:

Hook up air to inlet port of air cylinder.

Apply air pressure (60-125 psi) to disengage clutch. Rotate drum by hand to verify free spool.
Remove inspection plug, rotate drum until clutch jaws line up with drum jaws. Remove air pressure
so clutch jaws rest against drum jaws (See FIGURE 1). Rotate drum and observe if clutch jaws
engage fully with drum jaws (See FIGURE 2). Repeat three times.

Replace inspection plug.

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