Ramsey Winch Company

OWNER'S MANUAL
MODEL H-800 SERIES
DOW-LOK® EQUIPPED
INDUSTRIAL LOW-MOUNT WINCHES

Rated Line Pull (lbs.) 25,000

(kg) 9,060
Gear Reduction: 40:1
Worm RPM: 460 @ 30 GPM
Shipping Weight: 330 lbs. (150 Kg)
Layer of Cable 1 2 3 4 5**
*Rated line pull per (lbs.) 25,000 20,800 17,900 15,600 13,900
layer (kg) 11,349 9,430 8,110 7,070 6,300
(ft)* 35 75 125 180 240
*Cable Capacity
(m)* 10 22 38 54 72
FPM 18 22 26 29 33
*Line Speed
MPM 5.4 6.6 7.9 8.8 10.0
* These specifications are based on recommended wire rope of .63 inch (16mm) diameter 6x19
extra improved plow steel cable
** Fifth layer does not conform to SAE J706
Note: The rated line pulls shown are for the winch only. Consult wire rope
manufacturer for wire rope ratings.

Congratulations
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.

CAUTION: Read and understand this manual before installation and operation of
winch. See Safety Precautions.
 Contents
Performance Specifications . . . .COVER Instructions for Checking Assembly
Safety Precautions . . . . . . . . . . . . . . .2 Arrangement and Setting of
Techniques of Operation . . . . . . . . . . .3 Worm Brake . . . . . . . . . . . . . . . . . .7
Winch Maintenance . . . . . . . . . . . . . . .4 Adjustment of Clutch Air Shifter . . . . .8
Winch Mounting . . . . . . . . . . . . . . . . .4 Hydraulic System Requirements . . . . .9
Cable Installation . . . . . . . . . . . . . . . . .5 Trouble Shooting Guide . . . . . . . . . . .10
Adjusting the Oil Cooled Instructions for Overhaul . . . . . . .11-17
Worm Brake . . . . . . . . . . . . . . . . . . .5 Disassembly . . . . . . . . . . . . . . .11-14
Servicing the Oil Cooled Re-assembly . . . . . . . . . . . . . .14-17
Worm Brake . . . . . . . . . . . . . . . . . . .6 Dimensional Drawings . . . . . . . . .18-19
Re-assembling and Parts List and Parts Drawing . . . .20-23
Checking the Brake . . . . . . . . . . . . . . .6 Warranty . . . . . . . . . . . . .BACK COVER
Test for Proper Brake Assembly . . . . .7

Safety Precautions To Guard Against Possible Injury

A. Clutch must be totally engaged before starting the winch operation.
B. Do not disengage clutch under load.
C. Stay out from under and away from raised loads.
D. Stand clear of cable while pulling. Do not try to guide cable.
E. Do not exceed maximum line pull ratings shown in specifications.
F. Do not use winch to lift, support, or otherwise transport people.
G. A minimum of 5 wraps of cable around the drum barrel is necessary to hold load. Cable
set screw is not designed to hold load.

2
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 cable, while pulling a load, is not a problem, unless there is a cable
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 cable.
The Dow-Lok® clutch provides free spooling and clutch engagement with the cable drum.
With the clutch disengaged, the cable 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 ENGAGE CLUTCH
Dow-lok®: Run winch in the reverse “OUT” direction until the load is off the cable. Grasp
handle firmly and while pushing on the top of the handle with thumb for leverage, lift until pin
clears latching slots.
Pull handle toward “IN” position as far as it will go. Run winch in the “IN” direction until the
clutch springs to engagement and drum begins to turn. Do not attempt to lift a load
unless pin is fully into latching slots. Keep clear of spring-loaded handle during
automatic engagement.
Air Shifter: Run winch in the reverse “OUT” direction until the load is off the cable. Exhaust
air pressure from the air cylinder and run the winch in the “IN” direction until the clutch
springs to engagement and drum begins to turn.
TO DISENGAGE CLUTCH
Dow-lok®: Run winch in the reverse “OUT” direction until the load is off the cable. Grasp
handle firmly and while pushing on the top of the handle with thumb for leverage, lift until pin
clears latching slots.
Push handle to “OUT” position and fully insert pin into latching slots. Do not disengage the
clutch under load.
Air Shifter: Run winch in the reverse “OUT” direction until the load is off the cable. Run the
winch in the “OUT” direction until there is no load on the cable. Apply 70-90 PSI to the air
cylinder to disengage the clutch. Do not disengage the clutch under load.

3
WINCH MAINTENANCE
Adhering to the following maintenance schedule will keep your winch in top condition and per-
forming 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 oper-
ating condition so that hot oil gasses may escape.
3. Lubricate cable with light oil.
B. MONTHLY
1. Lubricate the various grease fittings located in the ends of cable drum shaft, end bearing,
clutch housing or clutch operating linkage. Any good grade of grease containing moly-
disulfide is acceptable.
2. In the case of jaw clutch winches, check the action of the sliding clutch, making sure it is
fully engaging and disengaging with the cable drum. Observe the jaws on both the clutch
and cable drum, checking for rounding of the driving faces. If rounding has occurred
they should be replaced immediately.
3. In the case of Dow-Lok® clutches, check the action of the locking ring. Make sure it is
spring loaded and free to move fully against the cable drum in the engaged position and
that it is pulled fully away from the cable drum and latched when disengaged.
4. Check the winch mounting bolts. If any are missing, replace them and securely tighten
any that are loose. Make sure to use only grade 5 bolts or better.
5. Check the torque setting of the oil cooled worm brake. Make any adjustments required,
following the procedure described in ADJUSTING THE OIL COOLED WORM BRAKE in the
Owner's Manual.
6. Check alignment of chain and sprockets and adjust as required to minimize wear.
7. Inspect the cable. If the cable has become frayed with broken strands, replace immedi-
ately.
C. ANNUALLY
1. Drain the oil from the winch annually or more often if winch is used frequently.
2. 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.
3. Refill the winch to the oil level plug with all purpose E.P. 140 gear oil.
4. Inspect frame and surrounding structure for cracks or deformation.
5. Gear wear can be estimated by rocking the drum back and forth and if necessary drain
oil and remove cover for closer inspection.
WINCH MOUNTING
It is most important that this winch be mounted securely so that the three major sections (the
clutch housing end, the cable drum and the gear-housing end) are properly aligned.

All standard H-800 Dow-Lok® series winches are furnished with recommended mounting
angles. Angle size is 1/2 x 3 x 4 high strength steel angle.

4
CABLE INSTALLATION
The Ramsey Model H-800 "Dow-Lok®” winch has two tapered pockets cast into the drum.
One pocket is for installations 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.
Insert the end of cable, opposite hook end, into the 11/16" dia. hole in drum barrel. Secure
cable to drum barrel, using setscrew furnished with winch. TIGHTEN SETSCREW SECURELY.
Carefully 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.

ADJUSTING THE OIL COOLED WORM BRAKE

The oil cooled, fully adjustable, automatic worm brake operates in the worm housing lubri-
cant, all parts being submerged in oil. When the brake wears to the point that the load
begins to drift, the brake can be adjusted as follows:
1. Loosen the adjusting screw lock nut.
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 over-heating, 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 spe-
cial adapter to fit the input shaft (worm) of
the winch. The adapter can be made by TUBING
welding a nut to the end of a piece of tubing
CAP
as shown in the following figure.
NUT
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 ADAPTER
will then act as a large socket. A torque SOCKET

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-800 Dow-Lok® should be 50 to 55 ft-lbs. 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, check the torque reading. Continue this proce-
dure until the proper torque reading is achieved. Then tighten the lock nut.

5
 BRAKE HOUSING
HUB
A
CAM PLATE
RETAINER PLATE
GASKET
THREAD SEAL PIN A
BALL
JAM NUT COMPOSITION
BRAKE DISC
ADJUSTING
LEAF SPRING
SCREW

2
COIL SPRING

1
BRAKE COVER
COVER
MOUNTING
SCREW
VIEW A-A
(LOOKING AT CAM
DIAGRAM 1 PLATE FROM WINCH)
WORM BRAKE
SERVICING OF THE OIL COOLED SAFETY 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.
6. Inspect parts as follows:
a) Composition brake discs are 1/4" thick when new. Replace if thinner than 3/16 or if
surfaces are glazed or burnt.
b) Inspect the flat, ground surface of the cam plate 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".
RE-ASSEMBLING AND CHECKING THE BRAKE
1. Press brake hub into place over worm shaft and key.
2. Assemble balls in appropriate slots of cam. 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. See instructions at right to determine proper ball slot setting. 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 3-3/4 pints 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.
6
TEST FOR PROPER 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 (hoisting 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 (cable out) for one minute. Brake housing should begin to
heat.
When these conditions exist, proper installation has been made. If heating becomes notice-
able when running the winch in forward rotation (hoisting 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.

INSTRUCTIONS FOR CHECKING ASSEMBLY ARRANGEMENT AND SETTING OF WORM

BRAKE
When the worm brake is assembled the brake must be set with the balls in the #1 or the #2
set of cam slots. (See View A-A, page 6). It is indicated on the name plate whether the balls
were installed in the #1 or the #2 slots at the factory.
Three factors determine which slots the balls should be in:
1. Direction cable winds on the drum. It normally winds over the top of the drum barrel.
2. The cut of the gear set, right or left gear. The last letter in the model number of the
winch, either R or L, designates right or left gear set. Example: R-20AR, R-30L, 700R,
800L.
3. The side of the winch that the input shaft is on. The Input Shaft is normally toward the
cab. Whether the winch has a gear box on the right or the left side of the winch does not
affect the brake setting.
When cable winds over the top of the drum, winch has a right cut gear and input shaft is
toward the cab, then the balls need to be in the #2 cam slots.
If any one of these three factors differ from those stated above, the balls need to be in the
#1 slots in the cam. A second change in these factors requires the original arrangement,
and if all three factors are different, the balls need to be in the #1 slots.

7
ADJUSTMENT OF CLUTCH AIR SHIFTER 3. Hook up air (70 to 90 psi) to inlet port of
1. Place winch assembly back into mount- air cylinder and disengage clutch. Look
ing frame and reattach using (8) mount- into the opening in the clutch housing
ing bolts and lockwashers. Torque and verify that the locking ring and
mounting hardware to 290 ft. lbs. each. retainer plate are not making contact.
Make sure that gear housing and clutch Locking ring and retainer plate must not
housing are not rubbing against drum make contact. There must be a clear-
flanges. ance (gap) of .09 inch (max.) between
the locking ring and retainer plate when
2. Place air shifter assembly #5 over the winch is fully disengaged. If there is
shifter shaft aligning clevis over flats of contact, the (4) capscrews #46 should
shaft. Secure clevis to shaft using clevis be loosened and the plate pulled away
pin #76 and cotter pin #75. Place from the drum approximately .06 inch.
shifter shaft in the "ENGAGED" position. Tighten screws securely and check
With the air cylinder shaft fully retracted, action to assure needed clearance.
push shifter assembly toward the drum Repeat adjustment procedure as needed
until all play is taken out of the shifter to acquire needed gap. Shift clutch 2 or
shaft. Secure shifter assembly to clutch 3 times to verify proper shifting of
housing using (4) capscrews #46 clutch. After final adjustment, torque (4)
(flanged hx. hd. serrated). Tighten capscrews #46 to 18 ft. lbs. each.
securely, but do not torque. Attach cover #43 using (4) capscrews
#61.

61 43

75

46
34
5

76 37

WINCH ASSEMBLY
.09 MAX. 53

21
RETAINER LOCKING
PLATE RING

8
HYDRAULIC SYSTEM REQUIREMENTS
Refer to the performance charts, below, to properly match your hydraulic system to H-800
Dow-Lok® winch performance. The charts consist of :
(1) Line pull (lb.) first layer vs. working pressure (PSI). STATIC (solid line) refers to hoisting
a suspended load from rest; DYNAMIC (dotted line) refers to maintaining the motion of a
moving load.
(2) Line speed, first layer (FPM) vs. Flow, gallons per minute (GPM).
Performance based on a motor displacement of 14.9 cubic inches with 30 GPM maximum
flow rate. See page 18 for motor port size.

H-800 Series Performance

25,000 lb. Duty Rating 40:1 Gear Ratio

25000 20
LINE SPEED, FPM
LINE PULL, LBS.

FIRST LAYER
FIRST LAYER

20000
C

15
MI
NA

15000
IC
DY

AT

10
ST

10000

5
5000

0 0
0 1000 2000 3000 0 10 20 30

WORKING PRESSURE, PSI FLOW, GPM

TYPICAL HYDRAULIC LAYOUT

9
 TROUBLESHOOTING GUIDE
CONDITIONS POSSIBLE CAUSE CORRECTION
CLUTCH INOPERATIVE OR 1. Dry or rusted shaft. 1. Clean and Lubricate.
BINDS UP 2. Bent yoke or linkage 2. Replace yoke or shaft
assembly.

CLUTCH HANDLE WON’T 1. Debris in clutch. 1. Clean and lube per page 15.
LATCH

OIL LEAKS FROM HOUSING 1. Seal damaged or worn. 1. Replace seal.

2. Too much oil. 2. Drain excess oil. Refer to
Techniques of Operation.
3. Damaged gasket. 3. Replace gasket.

LOAD DRIFTS DOWN 1. Worm brake has become 1. Replace brake disc. (See
worn. page 6)
2. Worm brake out of adjust- 2. Turn adjusting bolt clock-
ment. wise 1/4 turn or until load
does not drift.

WINCH RUNS TOO SLOW 1. Hydraulic motor worn out. 1. Replace motor.
2. Low flow rate. 2. Check flow rate. Refer to
Hydraulic Systems flow
chart, page 8.

CABLE DRUM WILL NOT 1. Winch not mounted square- 1. Check mounting. Refer to
FREESPOOL ly, causing end bearings to Winch Mounting, page 5.
bind drum.

CABLE BIRDNESTS WHEN 1. Drag brake disc worn. 1. Replace discs.

CLUTCH IS DISENGAGED

HYDRAULIC FLUID LEAKS 1. Damaged motor shaft seal. 1. Replace seal.

FROM HOLE IN ADAPTER

10
INSTRUCTIONS FOR OVERHAUL OF RAMSEY MODEL H-800
DOW-LOK®
Dis-assembly
Refer to parts list and parts drawing pages for
actual item numbers and corresponding parts
numbers.
(1)
Drain oil from gear housing by removing pipe
plug (item #63) from gear housing.
Shift clutch into the engaged "IN" position.
Remove frame angles (item #2) from winch
assembly.
(2)
Remove two capscrews (item #46) from clutch
housing (item #19) and unlatch shifter assembly.
Remove clutch housing from end of drum shaft.
Press in on retainer plate (item #67), to relieve the
spring tension and remove the retainer ring (item
#70).
Remove four capscrews (item #37), retainer plate
(item #67), springs (item #73) and spacer (item
#29).
(3)
Slide the locking ring (item #10) from the clutch.
NOTE: The locking ring cannot be removed unless
the clutch is engaged, with dowel pins (item #65)
seated in the shaft keyways.
Rotate the drum so the eight balls (item #33) and
four dowel pins (item #65) can be removed.
If necessary, the clutch (item #9) may be disassem-
bled from the drum by removing eight capscrews
(item #43). Slide drum (item #14) from drum shaft.
(4)
Remove key (item #24) from worm shaft.
Remove bearing cap (item #8) and gasket (item #56)
by unscrewing six capscrews (item #41) and lock-
washers (item 52).
Remove seal (item #68) from bearing cap and press
new seal into place.
Drag brake disc (item #13), spacer (item #76) and
spring (item #72) should be examined and replaced if
necessary.
11
(5)
Remove motor (item #62) from adapter plate (item
#26) by removing capscrews (item #51). Remove
adapter plate and coupling (item #2) from adapter
(item #3) by unscrewing eight capscrews (item
#48).
Remove key (item #24) from worm shaft.
Unscrew six capscrews (item #50) and remove
adapter from gear housing. Replace adapter seal
(item #70) and gasket (item #57).

(5a)
Remove motor (item #59) from adapter (item #2) by
removing two capscrews and lockwashers (item #48
& #52). Remove adapter (item #2) from gear housing
by removing six (item #47) capscrews. Replace pilot
seal (item #68) and gasket (item #54). Remove
thrust bearing (item #32) and thrust washers (item
#74).

(6)
Refer to page 5, SERVICING OIL COOLED SAFE-
TY BRAKE. Remove brake housing (item #18)
from gear housing by unscrewing six (item
#49) capscrews. Remove key (item #23)
from worm. Remove worm (item #30) and
bearings (item #34) from gear housing. Use a
soft hammer to gently tap input end of worm
and drive 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
(item #30) and bearings (item #34). Replace if necessary.

(7)
Remove gear housing cover (item #12) from gear
housing (item #20) by unscrewing eight capscrews
(item #40). 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 (item #58) and pull shaft (item
#27), with gear (item #17) and spacer (item #74)
attached, from gear housing.

12
 (8)
Check for signs of wear on gear teeth. If necessary,
replace gear.
Check lube fittings (item #78) for damage and
replace if necessary. Remove lube fittings (item
#78) and reducers (item #62) from ends of shaft,
if following Step 9, and reinstall after Step 9.

(9)
If shaft and/or gear hub is damaged, replace as
follows:
a. Tap keys (item #25) into short keyways
of drum shaft (item #27).
b. Press shaft (item #27) and keys through
gear hub (item #17) until end of keys on
long end of shaft are flush with hub.

(10)
Check gear housing bushing (item #5) and o-ring (item
#63) for signs of wear. Replace if necessary by pressing
old bushing from gear housing (item #20). Press new
bushing into place and insert new o-ring (item #61) into
groove inside of bushing.

(11)
Check drum bushings (items #35 & #36) for signs
of wear. Replace if necessary by pressing old bush-
ings from drum (item #14). Press bushing (item
#35) into bore in drum until it's flange is seated
against bottom of counterbore. Press bushing (item
#36) into opposite bore on drum until end of bush-
ing extends .50" from end of drum.

13
 (12)
Check end bearing bushing (item #36) for signs of
wear. If necessary, remove old bushing and press new
bushing into place.

(13)
Check cover bushing (item #5) and o-ring (item #61)
for signs of wear. Replace if necessary by pressing
old bushing from gear housing cover (item #12).
Press new bushing into place and insert new o-ring
(item #61) into groove inside of bushing.

RE-ASSEMBLY
(14)
Slide spacer (item #74) 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 (item #20).
Place greased end of shaft through bushing in
gear housing (item #20). Place gasket (item
#58) onto gear housing cover (item #12).
Apply grease to gear end of shaft and cover
bushing. Place cover onto shaft and secure to housing with eight (item #40) capscrews.
Tighten capscrews to 39 ft. lb. (52 Nm.) each.

(15)
Press bearing (item #34) onto worm
(item #30). 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 (item #56) onto brake housing
(item #18). Use six capscrews (item
#49) to secure brake housing to gear
housing. Tighten capscrews to 45 ft. lb.
(61 Nm.) each.
Place key (item #23) into keyway of
worm (item #30). Refer to page 6 for
reassembly and checking of worm brake.
14
(16)
Press bearing (item #34) 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 bearing cap (item #8) to gear
housing using six capscrews (item #41) with
lockwashers (item #52). Tighten capscrews to
39 ft. lb. (52 Nm.) each. Insert key (item #24)
into keyway of worm shaft.

(17)
Press bearing (item #34) onto worm and into
housing. NOTE: Be sure that thick shoulder
of bearings outer race (side with manufactur-
er's name and part number) is out, away from
worm threads. Attach adapter (item #3) to
gear housing using six capscrews (item
#50). Tighten capscrews to 45 ft. lb. (61
Nm.) each. Insert key (item #24) into key-
way of worm shaft. Slide coupling (item #2)
over end of worm shaft. Attach adapter plate
(item #26) to adapter using eight capscrews
(item #48). Tighten capscrews to 21 ft. lb.
(28 Nm.) each.
Place motor shaft, with key in keyway, into
coupling. Secure motor (item #62) to
adapter, using two capscrews (item #51).
Tighten capscrews to 102 ft. lb. (138 Nm.)
each.
(17a)
Place thrust washers (item #74) and thrust
bearing (item #32) over end of worm (item
#28) and into housing. Attach adapter (item
#2) with gasket (item #54) to housing,
using six (item #47) capscrews. Tighten
capscrews to 45 ft.lb. (61Nm.) each.
Insert pilot seal (item #68) into adapter and
carefully place motor shaft, with key in key-
way, through seal, so as not to damage seal.
Insert motor shaft into end of worm (item
#28). Secure motor (item #59) to coupling
using two (item #48) capscrews with lock-
washers (item #52). Tighten capscrews to
102 ft.lbs. (138 Nm.) each.

15
(18)
Place winch with gear housing cover down on work bench. Drum
shaft should be in vertical position. Set springs (item #72) into
pockets of gear housing with drag brakes (item #13) on top of disc
(item #76) and springs. Slide drum assembly (item #14) onto drum
shaft as shown.

(19)
Place clutch (item #9)
over end of drum shaft.
Align the clutch over
the pilot bushing in drum. Install the eight
capscrews (item #43) and torque the cap-
screws to 103 ft. lb. (139 Nm.) 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 (item #65) and eight balls (item #33).
Use molybdenum disulfide or graphite bearing
grease. Insert the four dowel pins (item #65)
and eight balls (item #33). In the engaged
position the balls are nearly flush with the
clutch.
Lightly grease the internal and external groove and bore in locking ring (item #10) and clutch
(item #9).
Slide locking ring onto the clutch. When fully engaged, the locking ring touches the clutch
flange and there is .71 to .73 inches between the end of the locking ring and the end of the
clutch.
(20)
Place four springs (item #73) over four
roll pins on retainer plate (item #67).
Install spacer (item #29) and retainer
plate and secure to clutch using four
capscrews (item #37). Tighten cap-
screws to 9.7 ft. lb. (13 Nm.) each.
Firmly seat the retainer ring (item #70)
into drum shaft groove.
Set the shifter assembly so that the
screw heads engage the external groove
in the locking ring (item #10). Push the
clutch housing (item #19) onto the
drum shaft and latch the shifter assem-
bly in the engaged "IN" position. Insert
the two capscrews (item #46).

16
(21)
Attach mounting angles (item #2) to
winch assembly. Use capscrews
(item #47 & #48) and lockwashers
(item #55). Tighten capscrews to
290 ft. lb. (393 Nm) each. Insert
plug (item #63) into hole in bottom
of gear housing. Remove plugs
(items #59 & 62) from top of hous-
ing. Pour 3 -3/4 pints of E.P. 140 oil
into hole and replace plugs.
Check the action of the clutch by
shifting and freespooling the winch
drum several times.
The shift pattern plate on top of the clutch housing is adjusted at the factory to provide reli-
able shifting of the Dow-Lok® clutch. If the plate should loosen or be removed, you must
readjust the plate. Shift the handle to disengage the clutch and hold against the internal stop.
With the latching pin in the "OUT" slots, push the shift pattern plate toward the cable drum.
Unsnap plastic lever cover from pattern plate. Tighten the four capscrews which hold the
plate to housing. Snap lever cover back into place around the pattern plate.

17
 Model 800 Dow-Lok®
H-800 / HY-800

18
 Model 800 Dow-Lok®
H-800 AIR SHIFTER

WINCH A B C D E F
MODEL INCHES INCHES INCHES INCHES INCHES INCHES
MM MM MM MM MM MM
10.62 15.00 13.81 19.38 52.00 5.69
H-800 144,5
269,7 381,0 350,7 492,2 1320,8

7.75 9.44 13.68 13.63 46.00 5.50

HY-800
196,8 239,8 347,4 346,2 1168,4 139,7

6.18 9.18
3.13 2.84 156,9 233,1
79,3 A 72,1

19
B
1/8-27NPT PORT
3.00
(70 PSI MIN. PRESSURE) 8.91
76,2 .50
(90 PSI MAX. PRESSURE) Ø12.13 6.87 2.13 226,0
54,0 12,7
FOR DISENGAGING CLUTCH 308,0 174,6
CLUTCH IS SPRING ENGAGED

4.00
101,6
.94
8.40 23,8 5.15
213,3 130,8
7.75 2.25
2.40 196,8 57,1
61,0 F
DIA. 2.25
57,1

1.25
31,7
2.50 2.50 10.38 11.20 6.54
C 63,5 D 63,5 263,6 284,4 166,1 1-1/16-20 O-RING PORT
8.36 2-PLACES 180° APART
E 212,3

DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS

20
Model H-800 Dow-Lok®
 PARTS LIST
MODEL H-800 DOW-LOK®
Item No. Qty. Parts No. Description Item No. Qty. Parts No. Description
1 1 276033 SHIFTER ASSEMBLY 40 8 414277 CAPSCREW 3/8-16NC X 1 LG HX HD GR5 NYLOK HVY P
2 1 299733 COUPLING ASSEMBLY 41 2 414399 CAPSCREW 3/8-24NF X 1-1/4 LG ALL-THRD GR5
3 1 300048 ADAPTER 42 8 414571 CAPSCREW 1/2-20NF X 1 LG HX HD GR5
4 2 302710 ANGLE - Y800 43 1 414603 CAPSCREW 1/2-20NF X 1-3/4 LG ALL-THRD GR5
5 2 302711 ANGLE - STD.
6 1 306035 SPRING - FLAT 45 2 414619 CAPSCREW 1/2-13NC X 2-1/2 LG HX HD ALL-THRD ZP
7 2 308083 BUSHING 46 4 414751 CAPSCREW 3/4-10NC X 1-3/4 GR5 NYLOK HVY PATCH
8 1 314007 CAM PLATE 47 4 414777 CAPSCREW 3/4-10NC X 1-3/4 GR5
9 1 314010 CABLE ANCHOR ("STD." DRUM ONLY) 48 8 414871 CAPSCREW 5/16-18NC X 1-1/4 LG SOC HD LOK-WEL
10 1 324151 CLUTCH 49 6 414897 CAPSCREW 3/8-16NC X 1 LG SOC HD
11 1 324318 LOCKING RING 50 6 414909 CAPSCREW 3/8-16NC X 1-3/4 LG SOC HD LOK-WEL
12 1 328027 COVER - BRAKE 51 2 414950 CAPSCREW 1/2-13NC X 1-3/4 LG SOC HD LOK-WEL
13 1 328122 COVER - GEAR HOUSING 52 1 418067 NUT 1/2-20NF HX JAM
14 2 330010 SHOE - DRAG BRAKE 53 4 418163 LOCKWASHER 5/16 MED SECT PLTD
15 1 332167 DRUM (STANDARD) 54 4 418184 WASHER - FLAT 3/8 ALUM
16 1 332172 DRUM ("Y" 800) 56 8 418249 LOCKWASHER 3/4 MED SECT
17 1 334188 GEAR - R.H. 57 2 442192 GASKET
18 1 338221 HOUSING - BRAKE 58 1 442194 GASKET

21
19 1 338235 HOUSING - CLUTCH 59 1 442195 GASKET
20 1 338242 HOUSING - GEAR 60 1 456008 FITTING - RELIEF
21 1 340011 HUB - BRAKE 61 1 456031 FITTING - LUBE
62 1 458048 MOTOR - HYD
23 1 342053 KEY 63 2 462013 QUAD-RING
24 1 342092 KEY 64 3 468002 REDUCER
25 2 342153 KEY 65 2 468011 PIPE PLUG
26 1 350535 PLATE - HYD. ADAPTER 66 4 470042 PIN - ROLL
27 1 352021 PLATE - RETAINER 67 4 470044 PIN - DOWEL
28 1 357498 SHAFT - DRUM (STD.) 68 4 470056 PIN - ROLL
29 1 357502 SHAFT - DRUM (Y800) 69 1 474030 PLATE - RETAINER
30 1 362224 SPACER 70 1 486068 SEAL - OIL
31 1 368082 WORM R.H. 71 1 486076 THREAD SEAL
32 2 400007 BALL - BRAKE 72 1 490025 RING - RETAINER
33 8 400011 BALL - CLUTCH 73 1 494010 SPRING
34 2 402045 BEARING - BALL 74 2 494022 SPRING - DISC
35 1 412051 BUSHING 75 4 494069 SPRING
36 2 412052 BUSHING 76 1 518016 THRUST WASHER
37 4 414038 CAPSCREW 1/4-20NC X 3/4 LG HX HD GR5 77 1 530007 DISC - BRAKE
38 4 414069 CAPSCREW 5/16-18NC X 3/4 LG HX HD 78 2 530094 SPACER - BRAKE
39 4 414111 CAPSCREW 5/16-18NC X 1 LG HX HD GR5 79 1 416059 SETSCREW ("Y" DRUM ONLY)
80 2 456039 LUBE FITTING
 52 36 61
69 55

27 57
62
63 28
53

51 77 60 46
39 1 16
70 68
48 60 45
54 78
73
85
44 75 59 41
18 42 4
35
82 56
9 65 11 43
37 80
29 8 84
13 31 5
79 87 81
10 14 67
32 48 21
38
35 83
88 58
34 64 25
4

22
33 20 7
46 60 13 17
88 84
86 76
22
45 60
64 19 74
24 80 72 23
30 6
49
33 76
15
3 26
66
71 72
23 12
2
40

47
73
50 6
70
Model H-800 Dow-Lok® 71
Air Shifter
 PARTS LIST
MODEL H-800 DOW-LOK® WITH AIR SHIFTER
Item No. Qty. Part No. Description Item No. Qty. Part No. Description
1 1 299695 AIR SHIFTER BRACKET ASSEMBLY 43 1 414603 CAPSCREW 1/2-20NF X 1-3/4 LG ALL-THRD GR5
2 1 299733 COUPLING ASSEMBLY 44 2 414619 CAPSCREW 1/2-13NC X 2-1/2 LG HX HD ALL-THRD ZP
3 1 300048 ADAPTER 45 4 414751 CAPSCREW 3/4-10NC X 1-3/4 GR5 NYLOK HVY PATCH
4 2 302710 ANGLE - Y800 46 4 414777 CAPSCREW 3/4-10NC X 1-3/4 GR5
- 2 302711 ANGLE - STD. 47 8 414871 CAPSCREW 5/16-18NC X 1-1/4 LG SOC HD LOK-WEL
5 1 306035 SPRING - FLAT 48 8 414897 CAPSCREW 3/8-16NC X 1 LG SOC HD
6 2 308083 BUSHING 49 6 414909 CAPSCREW 3/8-16NC X 1-3/4 LG SOC HD LOK-WEL
7 1 314007 CAM PLATE 50 2 414950 CAPSCREW 1/2-13NC X 1-3/4 LG SOC HD LOK-WEL
8 1 314010 CABLE ANCHOR ("STD." DRUM ONLY) 51 1 416061 SETSCREW 3/8-24NF X 1-1/4 LG
- 1 416059 SETSCREW ("Y" DRUM ONLY) 52 4 416214 SCREW #10-32NF X 1/4 LG RD HD Z/P
9 1 324151 CLUTCH 53 4 416262 SCREW #10-32NF X 3/4 LG HX SOC Z/P
10 1 324318 LOCKING RING 54 2 418035 NUT 3/8-16NC HX REG Z/P
11 1 328027 COVER - BRAKE 55 1 418041 NUT 3/8-24NF HX JAM
12 1 328122 COVER - GEAR HOUSING 56 1 418067 NUT 1/2-20NF HX JAM
13 2 330010 SHOE - DRAG BRAKE 57 4 418141 LOCKWASHER #10 MED SECT Z/P
14 1 332167 DRUM (STANDARD) 58 4 418163 LOCKWASHER 5/16 MED SECT PLTD
- 1 332172 DRUM ("Y" 800) 59 4 418184 WASHER - FLAT 3/8 ALUM
15 1 334188 GEAR - R.H. 60 8 418249 LOCKWASHER 3/4 MED SECT
16 1 370047 YOKE 61 1 424005 COTTER PIN
17 1 338221 HOUSING - BRAKE 62 1 424029 CLEVIS PIN
18 1 338235 HOUSING - CLUTCH 63 1 433016 AIR CYLINDER
19 1 338242 HOUSING - GEAR 64 2 442192 GASKET

23
20 1 340011 HUB - BRAKE 65 1 442194 GASKET
21 1 342053 KEY 66 1 442195 GASKET
22 1 342092 KEY 67 1 456008 FITTING - RELIEF
23 2 342153 KEY 68 1 456031 FITTING - LUBE
24 1 350535 PLATE - HYD. ADAPTER 69 1 456038 BREATHER VENT
25 1 352021 PLATE - RETAINER 70 2 456039 LUBE FITTING
26 1 357498 SHAFT - DRUM (STD.) 71 1 458048 MOTOR - HYD
- 1 357502 SHAFT - DRUM (Y800) 72 2 462013 QUAD-RING
27 1 358067 CLEVIS 73 3 468002 REDUCER
28 1 358069 SHIFTER SHAFT 74 2 468011 PIPE PLUG
29 1 362224 SPACER 75 4 470042 PIN - ROLL
30 1 368082 WORM R.H. 76 4 470044 PIN - DOWEL
31 2 400007 BALL - BRAKE 77 1 470045 PIN - ROLL
32 8 400011 BALL - CLUTCH 78 4 470056 PIN - ROLL
33 2 402045 BEARING - BALL 79 1 474030 PLATE - RETAINER
34 1 412051 BUSHING 80 1 486068 SEAL - OIL
35 2 412052 BUSHING 81 1 486076 THREAD SEAL
36 1 413074 COVER - AIR SHIFT 82 1 490025 RING - RETAINER
37 4 414038 CAPSCREW 1/4-20NC X 3/4 LG HX HD GR5 83 1 494010 SPRING
38 4 414111 CAPSCREW 5/16-18NC X 1 LG HX HD GR5 84 2 494022 SPRING - DISC
39 4 414126 CAPSCREW 5/16-18NC X 3/4 LG HX HD 85 4 494069 SPRING
40 8 414277 CAPSCREW 3/8-16NC X 1 LG HX HD GR5 NYLOK HVY P 86 1 518016 THRUST WASHER
41 2 414399 CAPSCREW 3/8-24NF X 1-1/4 LG ALL-THRD GR5 87 1 530007 DISC - BRAKE
42 8 414571 CAPSCREW 1/2-20NF X 1 LG HX HD GR5 88 2 530094 SPACER - BRAKE