Manual

913407-0207-A
INSTALLATION INSTRUCTIONS FOR KIT #256130
AIR SHIFTER FOR H-800 WINCHES
1. Remove winch from mounting frame by removing (8) mounting bolts and lockwashers. Remove
shifter yoke mounting screws and pull clutch housing from end of winch assembly.
2. Remove Dow-lok
®
shifter shaft from shifter yoke by driving roll pin from shifter yoke. Install 358069
shifter shaft, as shown, to shifter yoke by driving roll pin into yoke and shifter shaft. Apply grease to
the end of the drum shaft. Set the shifter so that the screw heads in yoke engage the external
groove in the locking ring. Push the clutch housing onto the drum shaft with the shifter shaft sticking
out through the slot in the top of the clutch housing. Attach shifter yoke to the clutch housing using
(2) shifter yoke mounting screws.
3. Place winch assembly back into mounting frame and reattach using (8) mounting bolts and
lockwashers. Torque mounting hardware to 290 ft. lbs. each. Make sure that gear housing and
clutch housing are not rubbing against drum flanges.
4. Place 299710 air shifter assembly over shifter shaft aligning clevis over flats of shaft. Secure clevis
to shaft using 424029 clevis pin and 424005 cotter pin. 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) 414126
capscrews (5/16-18 x 3/4 flanged hex head serrated). Tighten securely, but do not torque.
5. Hook up air (70 to 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 .09 inch
(max.) between the locking ring and retainer plate when the winch is fully disengaged. If there is
contact, the (4) 414126 capscrews should be loosened and the plate pulled away from the drum
approximately .06 inch. 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) 414126 capscrews to 18 ft. lbs. each.
Attach shifter cover to shifter bracket assembly using (4) 416214 #10-32 x 1/4" round slot head
screws.
414126 CAPSCREW
WINCH ASSEMBLY
CAPSCREW
416214
DUST COVER
PATTERN PLATE
MOUNTING SCREWS
REMOVE AND
DISCARD
SHIFTER
PATTERN
PLATE
DOW-LOK
SHIFTER SHAFT
SHIFTER YOKE
358069
SHIFTER SHAFT
470045
ROLL PIN
424005
COTTER PIN
.09 MAX.
424029
CLEVIS PIN
SHIFTER YOKE
MOUNTING SCREWS
LOCKING
RING
299710
AIR SHIFTER
ASSEMBLY
INLET PORT
CLUTCH HOUSING
(shown rotated 180 degrees
from standard mounting)
RETAINER
PLATE