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TABLE OF CONTENTS

Warning Tags Safety Guidelines Winch Operating Practices

1.0 General Information 1.1 User Responsibility and Safety Precaution 1.2 Introduction

1.2.1 Purpose 1.2.2 Model Number, Serial Number, and Options 1.2.3 Warranty 1.3 Equipment Description

1.3.1 Capabilities and Limitations 1.3.2 Specification and Descriptive Data 2.0 Functional Description 2.1 Major Assembles

2.1.1 Drive Assembles 3.0 Installation Instructions 3.1 Site Selection 3.2 Handling 3.3 Installation Procedures 3.3.1 Welding/Bolt Down

3.3.2 Requirements Prior to Start Up

Page 1 of 2

3.4 Installation Checkout

3.4.1 Phase-1 Installation Inspection 3.4.2 Phase-2 Start Up and Preliminary Test 3.5 Cable Installation 3.5.1 Cable Termination on Drum 3.5.2 Spooling Cable onto Drum 4.0 Operating Instructions

4.1 Operator Start-Up 4.2 Shutdown/Turn Off

5.0 Preventive Maintenance 5.1 Introduction 5.2 Maintenance Plan

5.2.1 Lubrication Schedule 5.2.2 Cleaning 5.2.3 Cable and Hoses 5.2.4 General Inspection

6.0 Component Removal/Replacement Appendices RAM Winch & Hoist Parts Information Performance Characteristics Derrickman General Assembly Drawing Derrickman General Arrangement Drawing Winch/Drum/Frame/Gearbox Assembly Air Schematic Air Motor Specifications & Parts List Gear Box Specifications & Parts List Disc Brake Assembly Control Valve Illustration & Parts List Regulator Specifications Filter Specifications Lubricator Specifications & Maintenance Shuttle Valve Pendant Control Assembly Pendant Controller Page 2 of 2

GENERAL GUIDELINES FOR SAFE OPERATION

The following warnings and precautions should be taken to ensure safe operating conditions.

Failure to remain alert and keep equipment in good operating condition could result in personal injury or death. To avoid such please read and understand this manual as well as all applicable laws and requirements for safe operation.

Keep a copy of this manual with the equipment at all times.

Be certain all operators of the equipment have been properly trained in the use of the equipment and have read the owners manual thoroughly.

!!WARNING!!

Keep hands, feet and any loose clothing away from rotating or moving parts. Never operate the equipment with any guards or safety equipment removed from winch.

Failure to do so may result in injury or death.

When maintaining the equipment be sure to tag Out of Service on power supply to prevent accidental operation or activation.

Do not alter or modify the equipment in any way without first contacting RAM Winch & Hoist Engineering Department as to the alteration type or extent. Failure to do so could result in damage to the equipment or injury to personnel.

WIN

CH

OP

ER

AT

ING

PR

AC

TIC

ES

P

os

t a

t O

pe

rati

ng

Sta

tio

n

F

orm

2008

1.

Rea

d th

e m

anuf

actu

rer'

s in

stru

ctio

ns

befo

re

oper

atin

g th

e w

inch

. 2

. A

lway

s in

spec

t,

test

m

aint

ain

and

oper

ate

this

w

inch

in

ac

cord

ance

wit

h A

mer

ican

Nat

iona

l St

anda

rds

Inst

itut

e Sa

fety

St

anda

rds

B30

.7.

3.

Nev

er L

ift

a lo

ad g

reat

er t

han

the

rate

d lin

e pu

ll of

the

win

ch.

4.

Use

the

rec

omm

ende

d si

ze w

ire

rope

for

load

to

be h

andl

ed.

5.

Nev

er u

se t

he w

ire

rope

as

a sl

ing.

6

. A

lway

s st

and

clea

r of

the

load

. 7

. U

nles

s th

e w

inch

is

desi

gned

for

per

sonn

el h

andl

ing,

nev

er u

se

the

win

ch f

or l

ifti

ng o

r lo

wer

ing

peop

le,

and

neve

r st

and

on a

su

spen

ded

load

. 8

. N

ever

car

ry lo

ads

over

peo

ple.

9

. N

ever

dis

enga

ge t

he c

lutc

h w

ith

a lo

ad a

pplie

d to

the

win

ch.

10.

Nev

er e

ngag

e th

e cl

utch

wit

h th

e w

inch

mot

or r

unni

ng.

11.

Alw

ays

rig

the

win

ch p

rope

rly

and

care

fully

, mak

ing

cert

ain

the

wir

e ro

pe is

pro

perl

y an

chor

ed t

o th

e dr

um.

12.

Bef

ore

each

shi

ft,

chec

k th

e w

inch

for

wea

r or

dam

age.

C

heck

th

e br

akes

, w

ire

rope

, ho

oks,

gui

des,

mou

ntin

g bo

lts,

etc

. L

ift

a ca

paci

ty l

oad

or a

nea

r ca

paci

ty l

oad

a fe

w i

nche

s of

f th

e fl

oor

and

che

ck t

he a

bilit

y of

the

bra

king

sys

tem

to

stop

and

hol

d th

e lo

ad w

itho

ut e

xces

sive

dri

ft, i

f th

e w

inch

is b

eing

use

d fo

r lif

ting

. 13

. N

ever

ope

rate

a w

inch

wit

h a

twis

ted,

kin

ked

or d

amag

ed w

ire

rope

.14

. P

erio

dica

lly i

nspe

ct t

he w

inch

tho

roug

hly

and

repl

ace

wor

n or

da

mag

ed p

arts

. K

eep

accu

rate

rec

ords

of

all

insp

ecti

ons

and

repa

irs.

15.

Fol

low

th

e lu

bric

atio

n in

stru

ctio

ns

prov

ided

by

th

e m

anuf

actu

rer.

16.

Do

not

atte

mpt

to

repa

ir t

he w

ire

rope

or

hook

s.

Rep

lace

hoo

ks

whe

n th

ere

is a

15%

incr

ease

in t

he t

hroa

t op

enin

g or

whe

n th

ere

is a

10%

ben

d as

sho

wn

by in

spec

tion

rec

ords

. 17

. K

eep

the

rope

cle

an a

nd w

ell

lubr

icat

ed.

Rep

lace

wir

e ro

pe t

hat

is f

raye

d.

18.

Eas

e th

e sl

ack

out

of t

he w

ire

rope

whe

n st

arti

ng.

Do

not

jerk

th

e w

inch

.

19.

If t

he d

rum

is

expo

sed

to p

erso

nnel

wal

kway

s, p

lace

a g

uard

ov

er t

he d

rum

. 20

. D

o no

t us

e yo

ur h

ands

to

guid

e th

e ro

pe o

nto

the

drum

whe

n w

indi

ng in

the

wir

e ro

pe.

21.

Be

cert

ain

ther

e ar

e no

obj

ects

in

the

way

of

the

load

or

hook

w

hen

oper

atin

g th

e w

inch

. 22

. D

o no

t us

e hi

gher

ai

r pr

essu

re

than

reco

mm

ende

d by

th

e m

anuf

actu

rer.

23.

Use

com

pres

sed

air

care

fully

. B

e su

re t

he h

ose

coup

lings

are

se

cure

, and

mak

e ce

rtai

n a

safe

ty c

hain

is p

rovi

ded

to a

void

hos

e w

hip

if t

he c

oupl

ing

fails

. 24

. W

ear

prop

er

clot

hing

to

av

oid

enta

ngle

men

t in

ro

tati

ng

mac

hine

ry.

25.

Be

cert

ain

the

air

supp

ly

is

shut

of

f be

fore

pe

rfor

min

g m

aint

enan

ce o

n th

e w

inch

. 26

. P

rope

rly

secu

re a

win

ch b

efor

e le

avin

g it

una

tten

ded.

27

. D

o no

t le

ave

a lo

ad s

uspe

nded

for

any

ext

ende

d pe

riod

of

tim

e.

Nev

er le

ave

a su

spen

ded

load

una

tten

ded.

28

. D

o no

t al

low

unq

ualif

ied

pers

onne

l to

oper

ate

a w

inch

. 29

. D

o no

t op

erat

e a

win

ch if

you

are

not

phy

sica

lly f

it t

o do

so.

30

. D

o no

t di

vert

you

r at

tent

ion

from

the

loa

d w

hile

ope

rati

ng a

w

inch

.31

. B

e ce

rtai

n th

e lo

ad i

s pr

oper

ly s

eate

d in

the

sad

dle

of t

he h

ook.

D

o no

t ti

p lo

ad t

he h

ook

as t

his

lead

s to

spr

eadi

ng a

nd e

vent

ual

failu

re o

f th

e ho

ok.

32.

Do

not

forc

e a

hook

into

pla

ce b

y ha

mm

erin

g.

33.

Nev

er o

pera

te a

win

ch b

eyon

d th

e po

int

whe

re l

ess

than

fou

r w

raps

of

wir

e ro

pe r

emai

n on

the

dru

m.

34.

Do

not

use

the

wir

e ro

pe a

s a

grou

nd f

or w

eldi

ng.

Do

not

atta

ch

a w

eldi

ng e

lect

rode

to

a w

inch

or

slin

g.

35.

Nev

er o

pera

te a

win

ch t

hat

mak

es e

xces

sive

mec

hani

cal

nois

e.

Rep

ort

the

prob

lem

imm

edia

tely

.

2,500 lbs.SWL @ 1st layer at 90 psig (utility rating).

470 ft. of 3/8" wire rope @ 8th layer

65

For temperatures above 80

APPENDICES

RAM Winch & Hoist Parts Information Performance Characteristics Derrickman General Assembly Drawing Derrickman General Arrangement Drawing Winch/Drum/Frame/Gearbox Assembly Air Schematic Air Motor Specifications & Parts List Gear Box Specifications & Parts List Disc Brake Assembly Control Valve Illustration & Parts List Regulator Specifications Filter Specifications Lubricator Specifications & Maintenance Shuttle Valve Pendant Control Assembly Pendant Controller

Parts Ordering Information When ordering parts, please provide the model and serial number for your unit. If possible, please supply us with the original purchase order. Call RAM Winch & Hoist Parts Department at (281) 999-8665 or fax your order to (281) 999-8666. For your convenience and future reference please take a few moments to add the following: Model Number _____________________. Job/Serial Number __________________. Date Purchased ____________________.

RAM PARTS DEPARTMENT

Phone 281-999-8665 Fax 281-999-8666

Win

ch D

esig

n / P

erfo

rman

ce C

hara

cter

istic

s

Win

ch M

odel

RA

M D

M20

40-1

0XK

3-15

Util

ity

Line

Pul

l, lb

s.20

60.0

Line

Spe

ed, f

pm45

W

ire R

ope

Dia

., in

3/8

Leng

th, f

t25

9N

o. o

f Lay

ers

5.0

K F

acto

r0.

09D

rum

Dia

., in

5.56

Flan

ge D

ia.,

in12

.0

Dru

m W

idth

, in

10.2

5

Dru

m R

pm23

.8

Torq

ue(ft

-lbs)

621.

00R

educ

tion

60.0

La

yer N

o.C

apac

ityA

ccum

ulat

edPi

tch

Rat

ed

Line

Spe

edFl

ange

(ft)

Cap

acity

Dia

Line

pul

l(fp

m)

Cle

aran

ce(ft

)(in

)(lb

s)(in

)

142

425.

9425

1137

2.8

247

906.

5822

6341

2.5

352

141

7.23

2060

452.

24

5619

87.

8818

9049

1.9

561

259

8.53

1746

531.

56

6632

59.

1816

2357

1.2

770

395

9.83

1515

610.

98

7547

010

.48

1421

650.

6

DM

2040

-10X

K3

DER

RIC

KM

AN

PA

RTS

LIS

TD

M20

40-1

0XK

3

AG06308R

AH00004R

DM

2040

-10X

K3

RAM P/N I400010R

AIR MOTOR

Serious Personal Injury May Occur If The Motor Is Allowed To Operate With The Exhaust Port Open Or Without Muffler

WARNING

RAM P/N I400010R

RAM P/N I400010R

RAM P/N AH00004C

Single ReductionWorm Gear Reducer

RAM P/N AH00004WORM GEAR REDUCER

Hollow Output Shaft Assembly

Double Input Shaft Assembly

PARTS ILLUSTRATION

Single Reduction Parts ListE n g i n e e r i n g D a t a

157

Item # DescriptionBasic Single Reduction Unit

1. Gear Housing2. Pipe Plug3. Vent Plug4. Splash Guard5. Input Cover6. O-Ring7. Hex Head Cap Screw8. Input Oil Seal9. Input Bearing

10. Input Bearing*11. Retaining Screw12. Input Shaft13. Output Cover14. Output Cover15. O-Ring16. Output Cover Gasket (as required)17. Output Oil Seal18. Output Bearing19. Hex Head Cap Screw

***20. Single Output Shaft***21. Double Output Shaft

22. Gear Spacer23. Gear Key (only used on size 2-5/8” center distance

and larger units)24. Output Gear (supplied only with output gear

on size 1-1/3” through 2-3/8” center distance units)25. Input Cover (only used on size 4-1/4” center

distance and larger units)26. Input Cover27. Input Oil Seal

*28. Retaining Ring - Shaft29. Double Input Shaft

170. Internal Pressure Compensation Chamber (optional)171. Internal Pressure Compensation Chamber Stem Plug172. Internal Pressure Compensation Chamber Stem Nut

*not used on 4-1/4” center distance and larger units

Quill Motor Flange Unit

30. Double Input Shaft40. Quill Motor Flange41. Input Oil Seal42. Hex Head Cap Screw43. Retaining Ring - Shaft44. Retaining Ring - Housing (only used

on size 4-1/4” center distance and larger units)45. Quill Input Shaft

Hollow Output Shaft Unit

50. Gear Housing51. Output Cover52. Output Oil Seal53. Output Bearing54. Gear Spacer

***55. Output Shaft 56. Setscrew57. Gear Key (only used on size 2-5/8” center distance

and larger units)

Item # Description

58. Output Gear (supplied only with output shaft on size 11/3” through 2-3/8” center distance units)

Mounting Bracket Options

70. Horizontal Mounting Foot71. Cap Screw72. High and Low Riser Bracket73. Hex Head Cap Screw74. “J” Mount Bracket75. Output Flange76. Machine Faced Output Cover (only used on size 2-

3/8” center distance and larger solid output shaft units)

77. Hex Head Cap Screw78. Torque Bracket79. Hex Head Cap Screw

Extended Bearing Unit

90. Flange91. Output Shaft92. Bearing93. Output Oil Seal94. Hex Head Cap Screw95. Pipe Plug96. Expansion Plug

*97. Flange Cover*98. Gasket*99. Hex Head Cap Screw

*only used on size 5-1/4” center distance and larger units

Long Motor Flange and Coupling Kit

110. “C” Face Motor Flange111. Hex Head Cap Screw112. Coupling Key - Reducer Shaft113. Setscrew - Reducer Shaft114. Coupling Gear - Reducer Shaft115. Coupling Sleeve116. Setscrew - Motor Shaft117. Coupling Gear - Motor Shaft118. Coupling Key - Motor Shaft

Vertical Shaft Required Parts(Supplied only when mounting position

involves a vertical shaft.)

*129. Output Cover*130. Output Cover*131. Output Bearing Grease Retainer132. Grease Fitting133. Sealed Ball Bearing (only used on size 1-3/4”

through 2-5/8” center distance units)**134. Input Cover**136. Input Bearing Grease Retainer

* Only used on size 4-1/4” center distance and larger units.** Only used on size 3” center distance and larger units.*** Supplied only with output gear on size 1-1/3” through

2-3/8” center distance units.

RAM P/N AH00004WORM GEAR REDUCER

PARTS DESCRIPTION

RAM P/N AH00004CSingle Reduction Worm Gear Reducer

LUBRICATION

To assist you in the proper selection of replacement lubricant, we recommend the following oils for the ambient temperatures specified:

Disc Brake AssemblyRAM P/N 827340

! WARNING

Read this manual carefully before installation and operation.

Follow the instructions and integrate this unit into your system with care.

This unit should be installed, operated and maintained by qualified personnel only.

Improper installation can damage your system.

Comply with all applicable codes.

FORM NO. L-20323-D-03001

INSTALLATION

NOTEThe following sections are arranged by model. Verify that you are in the correct section for your model.

FMBES-CC

1. Remove the six Socket Head Cap Screws (Item 11)and separate the two halves of the FMBES-CC.

2. Using four Socket Head Cap Screws (Item 34) andLock Washers (Item 35), secure the Female Pilot(Item 6) to the motor. Tighten the Socket Head CapScrews to the recommended torque (SeeFigure 1 and Table 1).

3. Install the customer supplied key into the motor shaft(See Figure 1).

4. Reassemble the two halves of the FMBES-CC (SeeFigure 1).

5. Apply a drop of Loctite® 242 to the threads of the sixSocket Head Cap Screws (Item 11) (See Figure 1).

6. Reinstall the six Socket Head Cap Screws (Item 11);then, alternately and evenly tighten them to 65 In. Lbs.[7.3 N•m] torque (See Figure 1).

7. Remove Pipe Plug (Item 30) (See Figure 1).

8. Tighten the Set Screw (Item 29) to lock the customersupplied key. Reinstall the Pipe Plug (Item 30) (SeeFigure 1).

Motor

Customersupplied key

6

3029

11

FIGURE 134/35

EUQROTDEDNEMMOCER

LEDOM 43METI

526 ]m•N5.56[.sbL.tF3.84

578 ]m•N5.56[.sbL.tF3.84

5211 ]m•N0.161[.sbL.tF57.811

5731 ]m•N0.161[.sbL.tF57.811

TABLE 1

AIR CONNECTIONS

NOTEFor quick response, install a quick exhaust valve and short air lines between the Control Valves andthe FMBES. Align the air inlet port to a down position to allow condensation to drain out of the Air Chamber of theFMBES.

In high-cyclic applications, Nexen recommends a 50 ms delay between the solenoid valve and the motor starter.In high-cyclic applications, a 50 ms delay between the solenoid valve and the motor starter is recommended.

FMBES-CC1. Mark both halves of the FMBES-CC with an alignment mark prior to disassembly.

with the alignment marks aligned.

2FORM NO. L-20323D-0300

LUBRICATION

NOTEPneumatically actuated devices require clean, pressure regulated, and lubricated air for maximum performanceand long life. The most effective and economical way to lubricate the FMBES is with an Air Line Lubricator, whichinjects oil into the pressurized air, forcing an oil mist into the air chamber.

Locate the lubricator above and within ten feet of the FMBES, and use a low viscosity oil such as SAE-10.

Synthetic lubricants are not recommended.

LUBRICATOR DRIP RATE SETTINGS

NOTEThese settings are for Nexen supplied lubricators. If you are not using a Nexen lubricator, calibration must replicatethe following procedure.

1. Close and disconnect the air line from the unit.

2. Turn the Lubricator Adjustment Knob clockwise threecomplete turns.

3. Open the air line.

4. Close the air line to the unit when a drop of oil forms inthe Lubricator Sight Gage.

5. Connect the air line to the unit.

6. Turn the Lubricator Adjustment Knob counterclockwiseuntil closed.

7. Turn the Lubricator Adjustment Knob clockwise one-third turn.

8. Open the air line to the unit.

MANUAL RELEASE OPERATION

NOTEThe Manual Release Set Screws (Item 26) must bealternately and evenly tightened to insure properoperation of the Manual Release feature.

1. Loosen the Jam Nuts (Item 27) until they are flush withthe tops of the two Set Screws (Item 26) (See Figure 2).

NOTECount and record the number of turns required forthe Set Screws (Item 26) to disengage the FMBES.

2. Alternately and evenly turn the Set Screws (Item 26)clockwise 1/2 turn at a time until the FMBES is released;then, secure the two Set Screws (Item 26) by turningthe Jam Nuts (Item 27) until they are flush with theHousing of the FMBES (See Figure 2).

3. To engage the FMBES alternately and evenly turn theSet Screws (Item 26) counterclockwise the samenumber of turns required to release the FMBES; then,secure the Set Screws with the Jam Nuts (Item 27) (SeeFigure 2).

FIGURE 2

Set Screw (Item 26)and

Jam Nut (Item 27)

FORM NO. L-20323-D-03003

TROUBLESHOOTING

FIGURE 3

BallBearing

FemalePilot

FrictionFacing

Rotor

DiscPlate

SetScrew

JamNut O-ring

Seal

WaveSpring

BallBearing

Shaft

CompressionSpring

Housing

Piston

FrictionDisc

TYPICAL FMBES-CC

MELBORP ESUACELBABORP NOITULOS

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.egagnesidoteruliaF

aoteudSEBMFehtotgnittegtonriA.noitcnuflamevlavlortnoc

dnanoitcnuflamevlavlortnocarofkcehC.yrassecenfievlavlortnocehtecalper

.slaeSgnir-OgnikaelronroW .slaeSgnir-OehtecalpeR

niroenilpsbuHehtnonoitacirbulfokcaL.rebmahCriAeht

riAro/dnaenilpsbuHehtetacirbuL.rebmahC

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.degagneesaeleRlaunaM .msinahcemesaeleRlaunaMegagnesiD

4FORM NO. L-20323-D-0300

PARTS REPLACEMENT

NOTEThe following sections are arranged by model. Verify that you are in the correct section for your model.

FRICTION FACING—FMBES-CC

1. Remove the six Socket Head Cap Screws (Item 11)(See Figure 4).

2. Remove the Pipe Plug (Item 30); then, loosen the SetScrew (Item 29) (See Figure 4).

3. Separate the two halves of the FMBES-CC (SeeFigure 4).

CAUTIONThe Disc Plate (Item 8) is under pressure from theCompression Springs (Item 14). Alternately and evenlyremove the Socket Head Cap Screws (Item 10). Alwayswear safety goggles when working with spring or tensionloaded fasteners or devices.

4. Remove the six Socket Head Cap Screws (Item 10);then, remove the Disc Plate (Item 8) from the Piston(Item 5) (See Figure 4).

NOTEThe Flat Head Machine Screws (Item 13) areassembled with an anaerobic thread lockingcompound. Inserting a properly fitting screwdriverinto the head of the Flat Head Machine Screw andstriking the end of the screwdriver with a hammerwill break the crystalline structure of the lockingcompound and allow removal of the Flat HeadMachine Screws. Never use an impact wrench toremove the Flat Head Machine Screws.

5. Remove the six Flat Head Machine Screws (Item 13)and the worn Friction Facing (Item 3) from the Rotor(Item 2) (See Figure 4).

6. Press the Shaft (Item 1), Ball Bearing (Item 9), and Rotor(Item 2) from the Housing (Item 7) (See Figure 5).

7. Remove the six Flat Head Machine Screws (Item 13)and the worn Friction Facing (Item 3) from the FrictionDisc (Item 4) (See Figure 5).

8. Install the new Friction Facing (Item 3) to the FrictionDisc (Item 4) using the six new Flat Head MachineScrews (Item 13). Tighten the six Flat Head MachineScrews (Item 13) to 20 In. Lbs. [2.2 N•m] torque (SeeFigure 5).

9. Carefully align the O.D. of the Ball Bearing (Item 9) withthe bore of the Housing (Item 7); then, press the Shaft(Item 1), Ball Bearing (Item 9), and Rotor (Item 2) backinto the Housing (Item 7) (See Figure 5).

10. Install the new Friction Facing (Item 3) to the Rotor (Item2) using the six new Flat Head Machine Screws (Item13); then, alternately and evenly tighten the six Flat HeadMachine Screws (Item 13) to 20 In. Lbs. [2.2 N•m] torque(See Figure 6).

10

8

13

3

11FIGURE 4

30

6

29

7

FIGURE 5

7

13

31

9

2

FIGURE 6

7

9

313

10 6

8

11

29

30

FORM NO. L-20323-D-03005

BALL BEARINGS, COMPRESSION SPRINGS, WAVED SPRING, AND O-RING SEALS FMBES-CC

1. Remove the six Socket Head Cap Screws (Item 11)(See Figure 7).

2. Remove the Pipe Plug (Item 30); then, loosen the SetScrew (Item 29) (See Figure 7).

3. Separate the two halves of the FMBES-CC (SeeFigure 7).

CAUTIONThe Disc Plate (Item 8) is under pressure from theCompression Springs (Item 14). Alternately and evenlyremove the Socket Head Cap Screws (Item 10). Alwayswear safety goggles when working with spring or tensionloaded fasteners or devices.

4. Remove the six Socket Head Cap Screws (Item 10);then, remove the Disc Plate (Item 8) from the Piston(Item 5) (See Figure 7).

5. Press the Shaft (Item 1), Ball Bearing (Item 9), and Rotor(Item 2) from the Housing (Item 7) (See Figure 8).

WARNINGSpecial attention should be exercised when workingwith retaining rings. Always wear safety goggleswhen working with spring or tension loaded fastenersor devices.

6. Remove the Retaining Ring (Item 16) from the Shaft(Item 1) (See Figure 9).

7. Press both old Ball Bearings (Item 9) off the Shaft (Item1) (See Figure 9).

8. Remove the Retaining Ring (Item 15) from the Shaft(Item 1) (See Figure 9).

9. Slide the Washer (Item 18) and Waved Spring (Item 17)from the Shaft (Item 1); then, install the new Waved Springand reinstall the Washer (See Figure 9).

FIGURE 7

10

8

11

FIGURE 8

7

1

92

30

6

29

7

11. Secure the Disc Plate (Item 8) to the Piston (Item 5)using the six Socket Head Cap Screws (Item 10); then,alternately and evenly tighten the six Socket Head CapScrews (Item 10) to 40 In. Lbs. [4.5 N•m] torque (SeeFigure 7).

12. Reinstall the FMBES-CC, referring to Steps 3 through 8of INSTALLATION (See Page 1).

6FORM NO. L-20323-D-0300

10. Reinstall the Retaining Ring (Item 15) (See Figure 9).

11. Pressing on the inner race of the two new Ball Bearings(Item 9), press the new Ball Bearings (Item 9) onto theShaft (Item 1) (See Figure 10).

12. Reinstall the Retaining Ring (Item 16) (See Figure 9).

WARNINGThe Friction Disc (Item 4) is spring loaded. Use 'C'clamps to maintain pressure on the Friction Disc(Item 4) while removing the six Socket Head CapScrews (Item 12). After the six Socket Head CapScrews have been removed, slowly release thepressure on the 'C' clamps. Always wear safetygoggles when working on spring or tension loadedfasteners or devices.

13. Alternately and evenly remove the six Socket Head CapScrews (Item 12) (See Figure 10).

14. Slowly release the pressure on the 'C' clamps; then,remove the 'C' clamps.

15. Remove the Friction Disc (Item 4) and old CompressionSprings (Item 14) from the Piston (Item 5) (SeeFigure 10).

WARNINGDo not apply excessive air pressure to slide thePiston (Item 5) out of the Housing (Item 7). Excessiveair pressure may result in personal injury or damageto the Piston and Housing.

16. Gently apply air pressure to slide the Piston (Item 5) outof the Housing (Item 7) (See Figure 10).

17. Remove the old O-ring Seals (Items 20 and 21) fromthe Piston (Item 5) (See Figure 10).

18. Clean the o-ring grooves of the Piston (Item 5) and o-ring contact surfaces of the Housing (Item 7) with freshsafety solvent (See Figure 10).

19. Lubricate the new O-ring Seals (Items 20 and 21) withfresh o-ring lubricant; then, install the new O-ring Sealsinto the Piston (Item 5) (See Figure 10).

20. Slide the Piston (Item 5) and new O-ring Seals (Items20 and 21) into the Housing (Item 7) (See Figure 10).

NOTERepair Kit No. 827301 contains nine CompressionSprings (Item 14). Refer to Table 3 for the correctnumber of Compression Springs required for yourModel FMBES-CC and the required output torque.

21. Install the new Compression Springs (Item 14) into thePiston (Item 5) (See Figure 10).

22. Place the Friction Disc (Item 4) on the Piston (Item 5)and Compression Springs (14); aligning the holes inthe Friction Disc with the tapped holes in the Housing(See Figure 10).

FIGURE 9

9

18

9

16

172

1

15

15

FIGURE 10

124

145

21

20

7

FORM NO. L-20323-D-03007

23. Using 'C' clamps, press the Friction Disc (Item 4) ontothe Piston (Item 5) (See Figure 10).

24. Apply a drop of Loctite® 242 to the threads of the sixSocket Head Cap Screws (Item 12) (See Figure 10).

25. Install the six Socket Head Cap Screws (Item 12); then,alternately and evenly tighten the Socket Head CapScrews (Item 12) to 30 In. Lbs. [3.4 N•m] torque. Removethe 'C' clamps (See Figure 10).

26. Carefully align the O.D. of the Ball Bearing (Item 9) withthe bore of the Housing (Item 7); then, press the Shaft(Item 1), Ball Bearing (Item 9), and Rotor (Item 2) backinto the Housing (Item 7) (See Figure 12).

NOTEApply Loctite 680® to the outer race of the Ball Bearing(Item 9).

27. Apply a drop of Loctite® 242 to the threads of the sixSocket Head Cap Screws (Item 10) (See Figure 12).

28. Secure the Disc Plate (Item 8) to the Piston (Item 5)using the six Socket Head Cap Screws (Item 10); then,alternately and evenly tighten the six Socket Head CapScrews (Item 10) to 40 In. Lbs. [4.5 N•m] torque (SeeFigure 12).

29. Reinstall the FMBES-CC, referring to Steps 3 through 8of INSTALLATION (See Page 1).

LEDOMTCUDORP

.ON

TUPTUOEUQROT).sbL.nI(

DERIUQERREBMUN

SGNIRPSFO

CC-SEBMF526

323728 .sbL.nI001 3

CC-SEBMF526

023728 .sbL.nI002 6

CC-SEBMF578

343728 .sbL.nI001 3

CC-SEBMF578

443728 .sbL.nI002 6

CC-SEBMF578

043728 .sbL.nI003 9

CC-SEBMF5211

063728 .sbL.nI004 9

CC-SEBMF5731

083728 .sbL.nI009 51

TABLE 3

FIGURE 11

7

1

92

FIGURE 12

6

8

9

1030

29

11

7

8FORM NO. L-20323-D-0300

FMBES-CC, 625

ITEM DESCRIPTION QTY

1 Shaft 12 Rotor 1

31,2 Friction Facing 24 Friction Disc 15 Piston 16 Female Pilot 17 Housing 18 Disc Plate 1

92 Ball Bearing 210 Socket Head Cap Screw 611 Socket Head Cap Screw 612 Socket Head Cap Screw 6

131,2 Flat Head Machine Screw 12 142 Compression Spring 3, 615 Retaining Ring (Ext.) 216 Retaining Ring (Ext.) 1

172 Waved Spring 118 Washer 1

202 O-ring Seal 1 212 O-ring Seal 124 Key (Not Shown) 126 Set Screw 227 Jam Nut 229 Set Screw 130 Pipe Plug 134 Socket Head Cap Screw 435 Lock Washer 4

1 Denotes Facing Kit item. Facing Kit Product No. 827302.2 Denotes Repair Kit item. Repair Kit Product No. 827301.

FMBES-CC, 875

ITEM DESCRIPTION QTY

1 Shaft 12 Rotor 1

31,2 Friction Facing 24 Friction Disc 15 Piston 16 Female Pilot 17 Housing 18 Disc Plate 1

92 Ball Bearing 210 Socket Head Cap Screw 611 Socket Head Cap Screw 612 Socket Head Cap Screw 6

131,2 Flat Head Machine Screw 12 142 Compression Spring 3, 6, 915 Retaining Ring (Ext.) 216 Retaining Ring (Ext.) 1

172 Waved Spring 118 Washer 1

202 O-ring Seal 1 212 O-ring Seal 124 Key (Not Shown) 126 Set Screw 227 Jam Nut 229 Set Screw 130 Pipe Plug 134 Socket Head Cap Screw 435 Lock Washer 4

1 Denotes Facing Kit item. Facing Kit Product No. 827302.2 Denotes Repair Kit item. Repair Kit Product No. 827301.

PARTS LIST

FIGURE 13FMBES-CC, 625 AND 875

11

16

2726

7

920

21

514

4

12

3

13

129

15

18

172

15

3

13

8

10 9

6

30

3435

RAM P/N AG04713MANUAL CONTROL VALVE

and

RAM P/N AG04714REMOTE CONTROL

PILOT OPERATED VALVE

RAM P/N AG04714R

MANUAL CONTROL VALVE 4 Way – 3 Position Manual Control

Valve Body Assembly 1 ¼” Ports

Hand Lever Assembly

Spring-Center Cap Assembly SA-4702-72-12

For 1 ¼” Valves

AG04713

RAM P/N AG04713C

PILOT OPERATED VALVE 4 Way – 3 Position Pilot Control

*** For Remote Control with Pendant Controller ***

Valve Body Assembly 1 ¼” Ports

SA-4702-83-12

Pilot Spring Center Cap Assembly

AG04714

CONTROL VALVE

PLATE ASSEMBLY

ITEM No. PART No. DESCRIPTION QTY.

1 400866 Valve Sub-Plate 1

2 400950 O-Ring 2

3 400660 Sandwich Plate 1

4 400951 O-Ring 1

5 400710 Thread Inlet Bushing 2

6 400950 O-Ring 2

7 400711 Adapter 1

8 400542 Hex Hd. Cap Screw 3/8 x 1 1/2” 4

9 400790 3/8 Lock Washer 4

10 400644 Allen Hd. 3/8 x 7/8” Cap Screw 5

11 400790 3/8 Lock Washer 5

12 400954 Allen Hd. 3/8 x 3/4” Cap Screw 3

13 400790 3/8 Lock Washer 3

14 400719 Air Motor 1

15 401134 Neopr. Spacer Ring 2

RAM P/N LB80050

REGULATOR

SPECIFICATIONS

Port Size 1 ½

Proof Pressure psig (Mpa) 220 (1.5)

Max. Operating Pressure psig (Mpa) 150 (1.0)

Temperature 23 ~ 140 (-5 ~ 60C

Pressure Regulating Range psig (Mpa) 7 ~ 120 (0.05 ~ 0.83)

Body AC2A-F

Bonnet ADC

Chamber AC2A-F

Valve Guide AC2A-F

Weight lbs (kgf) 5.51 (2.5)

FLOW CHARACTERISTICS

Conditions: Supply Pressure 100 psig PRESSURE CHARACTERISTICS

Supply Pressure – 100 psig Secondary Pressure – 30 psig (0.2 Mpa) Flow – 0.7 SCFM (20l/min)

* OPTIONALIf this component is supplied by others, the specifications of the substitute component should be comparable to the RAM LB80050

No. Name Material Part No.

5 Exhaust Valve Assembly --- 132586A

6 Main Valve Diaphragm Assembly --- 13275A

7 Valve Assembly --- 132752A

8 Regulating Spring SWPB 135053

9 Valve Spring SUS304 132713

11 Pilot Diaphragm --- 135019-1A

Dimensions

A B C D E F6.30

(160)

9.53

(242)

3.50

(89)

5.51

(140)

4.45

(113)

0.39

(10)

REGULATORRAM P/N LB80050

RAM P/N LB80040R

FILTER

Specifications

Pipe Size 1 1/4

Net Bowl Capacity oz. (cm3) 6.1 (180)

Weight lbs. (kgf) 6.94 (3.15)

Proof Pressure psig (Mpa) 220 (1.5)

Max. Operating Pressure psig (Mpa) 150 (1.0)

Operating Temperature Range 23 ~ 140 F (-5 ~ 60 C)

Filtration 40 m

Flow Characteristics

1 1/2(NPT)

RAM P/N LB80045R

LUBRICATOR

Specifications

Proof Pressure psig (Mpa) 220 (1.5)

Max. Operating Pressure psig (Mpa) 145 (1)

Operating Temperature Range 40 ~ 140 (5 ~ 60 C)

Recommended Lubricant Turbine Oil #1 (ISO VG32)

Pipe Size 1 ½” NPT

Oil Capacity (cm3) 500

Flow Rate /n/min 12500

®

ACCESSORIES

4

Functional DescriptionShuttle Valves have a free moving shuttle that blocks one of twoinlet ports while the other inlet port is connected to the (com-mon) outlet port. When a pressure signal enters the portblocked by the shuttle, it will cause the shuttle to shift over toclose the opposite inlet port. The shuttle will stay there while theline or chamber connected to the outlet port is charged and/ordischarged and will only shift when pressure is applied to theinlet port it is blocking at that time.In logic terms a shuttle valve is an 'OR' - function.

PressuresPressure range– Pneumatic: 5 to 200 psi (0.35 to 14 bar)

Hydraulic: 5 to 500 psi (0.35 to 35 bar)

Symbol

MountingPreferably with the centerline of the two inlet ports horizontal.As shown in the drawing above.

Sizes/Connections/Types/Dimensions/Weights*Porting Product Number Dimensions in inch (mm) Flow Cv (Kv) Weights in lbs (kg)

'P' brass st. steel 'A' 'B' 'C' brass st. steel brass st. steel1/8 NPT SV-2 2.0 (51) 1.5 (38) 1.0 (25) 0.8 (12) 0.57 (0.26)1/4 NPT SV-3 SV-3-316 2.0 (51) 1.5 (38) 1.0 (25) 0.8 (12) 0.5 (7) 0.57 (0.26) 0.33 (0.15)3/8 NPT SV-4 2.5 (64) 1.9 (48) 1.3 (32) 1.6 (23) 1.10 (0.50)1/2 NPT SV-5 2.5 (64) 1.9 (48) 1.3 (32) 2.1 (30) 1.10 (0.50)3/4 NPT SV-6 3.5 (89) 2.8 (70) 1.5 (38) 6.5 (84) 2.16 (0.98)

* For Subplate Mounting Shuttle Valves Consult Factory†conforms to NACE standard MR-01-75

SHUTTLE VALVESa range of Shuttle Valves in different sizes, made from Brass or 316 Stainless Steel

General DescriptionVERSA Shuttle Valves are constructed of solid Brass or 316Stainless Steel, with resilient seals providing tight shut off.Shuttle valves are 3/2 valves, primarily used to charge and dis-charge a pressure line or chamber from two - or more -sources. A typical schematic is shown below:

MaterialsType: Brass Stainless Steel

Body: Brass 316 Stainless Steel†

Shuttle: Nylon(Zytel) 316 Stainless Steel†

Seals: NBR (Nitrile) FKM (Fluorocarbon) Screws: Plated Steel 316 Stainless Steel†

®

1 2 3

OUT

IN IN

RAM P/N AG03315R

MODEL DM2040-10XK3RAM Winch & Hoist 02/09