User Manual

ManualsBrandsRamsey Winch ManualsFor the carGEARBOX REPLACEMENT KIT RAMSEY/AUBURN TO QGBX RPH20/25 256115

GEARBOX REPLACEMENT KIT

#256115

INSTALLATION INSTRUCTIONS

FOR RPH 20000/25000 WINCHES

WITH AUBURN GEARBOXES

NOTE: Refer to pages 7 and 8 for complete parts list and exploded parts diagram of winch with replacement

(Quantum) gearbox and associated parts. Item numbers denoted with * are from the Gearbox Replacement

kit. See parts list for kit on page 6.

1. Drain oil from gear end housing (item

#9) by removing pipe cap (item #44)

from pipe nipple in end bearing. Remove

reducer (item #42) and relief fitting (item

#36). Set aside pipe cap, reducer, and

relief fitting.

Remove air cylinder from gear end by

removing 4 screws (item #24). Pull air

cylinder from gear end assembly. Make

sure washer (item #26) comes off with

air cylinder. Set aside air cylinder and

washer.

2. Disconnect tube (item #47) from

elbows (item #30), as shown.

Remove motor (item #38) and

gasket (item #33) by removing

(2) capscrews (item #19).

AIR CYLINDER

Summary of content (8 pages)

PAGE 1
GEARBOX REPLACEMENT KIT #256115 INSTALLATION INSTRUCTIONS FOR RPH 20000/25000 WINCHES WITH AUBURN GEARBOXES NOTE: Refer to pages 7 and 8 for complete parts list and exploded parts diagram of winch with replacement (Quantum) gearbox and associated parts. Item numbers denoted with * are from the Gearbox Replacement kit. See parts list for kit on page 6. 36 1. Drain oil from gear end housing (item #9) by removing pipe cap (item #44) from pipe nipple in end bearing.
PAGE 2
0 3. Remove brake assembly (item #32) by removing (2) mounting screws (item #20) that attach brake to end bearing (item #8). Remove gasket (item #35) from end bearing. 32 10 35 8 4. Take note of mounting configuration for proper mounting of parts during re-assembly. Remove winch from upright mounting frame (item #2) by removing (4) capscrews and lockwashers. Pull motor end bearing (item #8) from drum assembly (item #1). 17 25 8 16 25 17 25 1 2 16 25 9 5.
PAGE 3
5* 6. From new Gearbox Replacement kit, place Gear End Assembly (item #2*) on workbench with gearbox cover down (as shown at right). Slide shifter shaft (item #4*) with washer (item #5) over it into the Gear End Assembly, with long splined end going in first. Mesh splines with input sun gear in gearbox. About 1/2” of the end of the shifter shaft should protrude through gearbox cover when it is all the way in.
PAGE 4
8. Carefully set motor end bearing on drum assembly. Secure motor end bearing to drum using C-clamp. Install winch in upright mounting frame using 4 capscrews (items #16 & #17) and lockwashers (item #24). Tighten securely. 17 25 8 16 25 1 17 25 2 16 25 9. Place gasket (Item #8*) into position on motor mounting surface of end bearing (item #8). Insert brake shaft into coupling. Use (2) screws (item #20) to attach brake assembly to motor end bearing. Torque capscrews to 85 ft lbs each.
PAGE 5
38 10.Attach motor (item #38) with well oiled gasket (item #7*) to brake (item #32). Use (2) capscrews (item #19) and torque to 74 ft. lbs. each. Securely connect tube (item #47) to elbow (item #30), in valve, and brake (item #32). 47 19 19 7* 30 11.Slide washer (item #26) over setscrew and against nut attached to air cylinder rod. Install air cylinder into gearbox cover making sure the setscrew in end of cylinder rod goes in hole in end of shifter shaft.
PAGE 6
Kit #256115 Parts List 1 5 3 4 2 7 5 6 8 PARTS LIST Item Qty. Part No. No. 1 1 296575 2 1 296609 3 1 324294 4 1 358073 5 2 418462 6 1 442217 7 1 442215 8 1 442224 Description OUTPUT COUPLING ASSY GEAR END ASSY COUPLING - SHAFT SHIFTER SHAFT CLUTCH WASHER GASKET - AIR CYLINDER GASKET - BRAKE & MOTOR END GASKET - BRAKE OUTPUT FACE RAMSEY WINCH COMPANY 6 P.O. Box 581510• Tulsa OK 74158-1510 Telephone: (918) 438-2760 • Fax: (918) 438-6688 Visit us at www.ramsey.
PAGE 7
30 20 30 33 16 32 47 25 45 20 Winch Assembly 18 48 19 38 19 8 10 35 14 5 LONGEST SPLINE 28 17 25 10 14 7 11 6 28 1 46 22 39 36 41 43 44 42 2 15 9 3 13 4 21 40 26 27 34 31 29 37 23 24
PAGE 8
QTY.