catalina aml336a-250-38 rs9032-rs9066 2-4-13 - … of the hoist drum. do not operate a damaged or...

Instructions, Parts and Maintenance Manual

CATALINA

MODEL AML336AK

AIR Personnel Hoist

Warning! Review “WINCH OPERATING PRACTICES” Prior to use.

Always operate, inspect and maintain this winch in accordance with American National Standards Institute Safety Code (ANSI B30.7) and any other applicable safety codes and regulations. This winch is only a component of the lifting system, which must be designed by qualified personnel.

TABLE OF CONTENTS

Warning Tags Personnel Hoist Safety Instructions Safety Guidelines Hoist Operating Practices Warning Labels Supplied on Hoist

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 2.2 System Description 2.2.1 Brakes 2.2.2 Wire Rope 2.2.3 Emergency Lift and Lower 2.2.4 Maintaining Dead Wraps on Drum 2.2.5 Overload Protection of Hoist 2.2.6 Emergency Stops 2.2.7 Slack Wire Detection and Safety Shutoff 2.2.8 De-Rail Protection 2.2.9 Travel Limit Switch 2.2.10 Speed Controls

2.2.11 Cable Shields 3.0 Installation Instructions Page 1 of 2

3.1 Site Selections 3.2 Handling 3.3 Installation Procedures 3.3.1 Welding/Bolt Down 3.4 Requirements Prior to Startup 3.5 Wire Rope Installation

3.5.1 Rigging 3.6 Slack Limit Setting 3.7 Travel Limit Adjustment 4.0 Operating Instructions 4.1 Hoist Controls 4.2 Brakes 4.3 Emergency Stop 4.4 Manual Override 4.5 Emergency Operating Procedures 5.0 Maintenance Procedures 5.1 Frequent and Periodic Inspections Appendices Drawings Drawing Number General Assembly 406931 Levelwind Assembly 406943 Levelwind Guard Assembly 406972 Basic Catalina Assembly 406932 Automatic Brake Assembly 406958 Pressure Roller Assembly 406962 Brake Actuator Assembly 406263 Cable Retainer Assembly 407250 Drum Assembly 406938 Control Console Assembly 406940 Air Schematic 407028 Basic Winch Assembly 407009 RAM Winch & Hoist Load Test Procedures Gearbox Assembly Illustrations and Instructions Miscellaneous Manufacturer Data Sheets Page 2 of 2

WARNING TAG

Read the latest edition of ASME B30.7. Comply with all Federal, State and local rules. It is the customer's responsibility to use this hoist with adequate factors of safety for the rated load, plus the weight of the hoist and attached equipment. A registered structural engineer should review handling procedures.

! WARNING ! Failure to follow these warning signs may result in death, severe injury or property damage: Do not operate this hoist before reading the operation

and maintenance manual. Do not lift more than rated load. Do not allow less than three wraps of wire rope to

remain on drum at all times. Operator must stay in view of the hoist drum.

Do not operate a damaged or malfunctioning hoist. Do not remove or obscure warning labels.

CATALINA PERSONNEL HOIST

MODEL NUMBER AML336AK The items described in the following instructions are essential to insure that the hoist is installed, operated and maintained in a manner that provides a high safety level in order to prevent personal injury or property damage. Thoroughly familiarize yourself with the symbols and indications shown below before proceeding in this manual. EXPLANATION OF MARKINGS

MARKING MEANING OF MARKING

! DANGER

Indicates that errors may lead to very serious injury or death.

! WARNING

Indicates that errors may lead to injury (*1) or cause property damage (*2).

*1 Such injuries as pinching, cuts, abrasions, etc. that may not require

hospitalization or long periods of treatment. *2 Physical property damage refers to a wide range of materials or assets. EXPLANATION OF SYMBOLS

SYMBOL MEANING OF SYMBOL

INDICATES PROHIBITION (DON’T DO IT) What is prohibited will be described in or near the symbol in either text or picture form.

!

INDICATES MANDATORY (MUST BE DONE) What is mandatory will be described in or near the symbol in either text or picture form.

INDICATES DANGER What is mandatory will be described in or near the symbol in either text or picture form.

INDICATES WARNING What is mandatory will be described in or near the symbol in either text or picture form.

LIMITS OF PURPOSE AND USE This hoist is to be used for raising and lowering personnel only. It was designed and built to handle personnel on a limited basis. USAGE

! DANGER

Prohibited

Never use this hoist for lifting or lowering personnel to a separate floating platform or vessel. This could result in serious injury or death.

Never install and/or operate this hoist without meeting all the

applicable requirements as specified by the proper governing bodies (i.e. NORSOK, NPD and DNV). Failure to do so could result in severe injury or death.

Never operate this hoist without proper training of the

equipment and safety precautions of a complete lifting system. Failure to do so could result in severe injury, death or property damage.

Do not use this hoist without all safety devices, guards and

original specified equipment in place and operable. Failure to do so could result in serious injury or death.

Do not use this equipment without the complete lifting system

being declared in conformance for operation. Failure to do so could result in serious injury or death.

TRANSPORTATION

! WARNING

Prohibited

Never lift this hoist in a manner other than as described in the manual. Failure to do so may cause damage to the equipment or falls resulting in injury.

Never strap or tie down the hoist over the guards or covers.

This may damage them or cause them to come off allowing the unit to come loose and fall, slide or drop, resulting in injury or damage.

INSTALLATION

! DANGER

Prohibited

Never attach the hoist base to a foundation unless properly reviewed by a competent Engineer. Failure to do so could result in injury, death or equipment damage.

Never use bolts to mount the hoist to its base other than those

specified in the manual. Failure to do so could result in injury, death or property damage.

!

Mandatory

There must be an adequate foundation, which will withstand a minimum of five (5) times the maximum pull capability of the hoist, for the hoist base to be welded or bolted to. If the foundation is not adequate, it could be damaged or pulled out by the hoist.

Use the proper manufacturer specified bolts to secure the

hoist to the base. If the proper bolts are not used, and fail, the hoist could be pulled off the base.

Torque the bolts to the proper setting as specified. Use a

calibrated torque wrench to ensure this. Over-torqued bolts may be over-stressed and yield, causing the hoist to break loose. Under-torqued bolts may allow the hoist to move slightly on the base.

Provide and connect a clean air supply to the hoist, which is

regulated to not exceed 100 PSI. If the air supply is not clean, it may cause the hoist to respond improperly. If the air pressure exceeds the maximum, it may cause component damage.

Review all installation instructions as outlined in the manual.

Use without following the proper installation procedures may cause equipment malfunction or damage.

! DANGER

Prohibited

Never operate this equipment without hoist and safety precaution training. This includes all items pertaining to the complete lifting system, of which the hoist is a component. Failure to do so could cause severe injury, death or equipment damage.

Prohibited

Never operate the hoist unless all safety mechanisms are in place and working properly, and all hoist components are in proper working order. Failure to do so could result in severe injury or death.

Never allow untrained personnel or personnel not directly

involved in the operation to loiter about the hoist during operation. Failure to do so may cause the hoist operator to become distracted and could result in injury, death or equipment damage. This could also result in injury to the loiterer.

!

Mandatory

The operator must inspect the hoist prior to operation to ensure that the unit is in proper working order. Failure to inspect could lead to malfunction or result in an accident.

! WARNING

Prohibited

Never lift a load greater than the rated line pull of the hoist. This will exceed the hoist limitations and could result in malfunction.

Never operate the hoist with twisted, kinked or damaged

wire rope. This could lead to rope failure and result in rope breakage.

Never operate the hoist without guards in place. Failure to

keep the guards in place could result in foreign items getting caught in the rotating portion of the hoist or personnel getting caught and injured in the rotating drum area.

Never leave a load suspended for an extended period of time,

if not necessary, or leave it unattended. If anyone were to tamper with the hoist or should something inadvertently cause the hoist to operate, the rider could be injured.

This hoist must not be placed in operation until the complete

lifting system has been declared safe for operation. Failure to do so could result in injury, death or property damage.

Never use the wire rope as a sling. This could cause damage

to the rope and cause premature rope failure. Do not operate the hoist if you are not mentally alert and

physically able to do so. Failure to do so could result in improper operation, which could lead to damage to the equipment and possible injury.

!

Mandatory

Anyone operating this hoist must read and understand the operating practices and all safety precautions in the operation manual. If the operator is not properly trained, they may misuse the hoist and cause damage to the equipment or personnel injury.

A clear view of the complete hoist and cable must be

maintained. This also includes the rider on the hoist rope. Failure to do so could result in placing the rider in a hazardous situation.

Make sure that the immediate area around the hoist is clear

of any trip hazards or slippery spots to prevent the operator, rider or anyone else from falling into the hoist or wire rope.

Keep any loose gear, clothing, long hair, and hands or feet

away from the wire rope, hoist levelwind and hoist drum. These items are in motion and could catch onto or pull item catching onto them into the hoist. They could also smash, pinch or cause even more severe injury.

Do not allow personnel to pass under a suspended rider.

There is a possibility of falling objects, which could hit and injure them.

A safety meeting must be conducted prior to operations with

all personnel involved to bring attention to the requirements of the operation, assess risks involved, establish duties and assignments and any other items or requirements. Failure to do so could result in numerous problems in operation and create hazards, which could result in injury and equipment damage.

Hoist must have all operation indicator tags pertaining to

controls properly affixed and in legible condition. Failure to do so could cause improper operation.

The operator and/or other personnel involved in the

operation must wear all applicable personal protective equipment due to the possibility of falling objects.

When operations are completed, the operator must secure the

hoist properly. The air supply to the hoist must be turned off to prevent inadvertent operation.

All hoist controls must be maintained in original condition as

supplied by the manufacturer. The controls are supplied with safety devices to prevent inadvertent operation.

MAINTENANCE AND REPAIR

! DANGER

Prohibited

Do not perform any repairs or maintenance on this equipment unless you are a trained, qualified technician with experience in this type of equipment. Failure to do so could result in severe injury, death and property damage. This could also cause operation problems if the equipment is not maintained or repaired properly due to inexperience.

Routine maintenance or repair of the hoist must not be

performed if a rider is suspended. This could result in dropping the rider if proper precautions to set the brakes are not followed.

Do not replace or repair any parts unless they meet the original

manufacturer specifications. Failure to do so may result in improper operation and cause severe injury or death.

Do not place the hoist back into service after any repairs have

been made which involved the drive system, air system or brake system until the unit has been properly tested. This will also require possible resetting of load limiting and system pressure control devices. Failure to do so may result in the possibility of excessive pull capacity, which could result in injury or death.

! WARNING

!

Mandatory

Hoist must be tagged Out of Service to perform routine repairs

or maintenance. Failure to tag out could result in the unit being used in an inoperable condition. This could result in damage or injury.

All warning tags supplied with the hoist must be kept affixed

to the unit and in legible condition. Failure to do so could cause injury.

This equipment must be maintained properly on a regular

maintenance schedule as required by the manufacturer or any regulatory body that may apply. This must be documented to provide records of time intervals. Failure to do so may result in improper maintenance intervals and could impair operation or severely decrease the life of the component or unit.

!

Mandatory

This hoist does contain petroleum lubricants. Checking or

changing of such requires proper handling and disposal as per applicable regulatory bodies.

Maintenance or repairs should be performed with the air

supply turned off. The system is pressurized when the air is on and a possible blow out of hoses, fittings or components could result, depending on the nature of repair. It would also be possible to get unwanted motion or operation.

All rating tags must be maintained as affixed to the unit and

legible. Failure to do could result in misuse. All loose gear, fittings, hardware, sheaves or pulleys used in

conjunction with this hoist must be maintained as required by applicable regulatory body. Failure to do so may cause hoist operation problems.

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. Keep hands, feet and any loose clothing away from rotating or moving parts. Never operate the equipment without the proper guards or safety equipment required for a complete hoist system. 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. Keep all warning tags on hoist in good legible condition and placed in areas on the unit that are highly visible and especially close to areas which could be considered hazardous. This hoist is a component of a lifting system. The complete lifting system is the purchaser’s or user’s responsibility and all safety guards, regulators, mufflers, wire rope or any other items required for a safe system must be specified and installed by same. Failure to do so may result in severe injury, property damage, or death. Wire rope, safety devices and other ancillary components are available and can be supplied with the unit as additional adders. Check with your supplier to determine what your specific unit is supplied with as standard. If you are unsure of your system or the requirements for safe operation, we recommend you consult with OSHA, ANSI, ASME, API or any other accredited association or a professional engineering firm.

WIN

CH

OP

ER

AT

ING

PR

AC

TIC

ES

Po

st a

t Ope

ratin

g St

atio

n

Fo

rm 2

008

1.

Rea

d

the

man

ufa

ctu

rer'

s in

stru

ctio

ns

bef

ore

oper

atin

g th

e w

inch

. 2

. A

lway

s in

spec

t,

test

m

ain

tain

an

d

oper

ate

this

w

inch

in

ac

cord

ance

wit

h A

mer

ican

Nat

ion

al S

tan

dar

ds

Inst

itu

te S

afet

y S

tan

dar

ds

B30

.7.

3.

Nev

er L

ift

a lo

ad g

reat

er t

han

th

e ra

ted

lin

e p

ull

of

the

win

ch.

4.

Use

th

e re

com

men

ded

siz

e w

ire

rop

e fo

r lo

ad t

o b

e h

and

led

. 5

. N

ever

use

th

e w

ire

rop

e as

a s

lin

g.

6.

Alw

ays

stan

d c

lear

of

the

load

. 7

. U

nle

ss t

he

win

ch i

s d

esig

ned

for

per

son

nel

han

dli

ng,

nev

er u

se

the

win

ch f

or l

ifti

ng

or l

ower

ing

peo

ple

, an

d n

ever

sta

nd

on

a

susp

end

ed lo

ad.

8.

Nev

er c

arry

load

s ov

er p

eop

le.

9.

Nev

er d

isen

gage

th

e cl

utc

h w

ith

a lo

ad a

pp

lied

to

the

win

ch.

10.

Nev

er e

nga

ge t

he

clu

tch

wit

h t

he

win

ch m

otor

ru

nn

ing.

11

. A

lway

s ri

g th

e w

inch

pro

per

ly a

nd

car

efu

lly,

mak

ing

cert

ain

th

e w

ire

rop

e is

pro

per

ly a

nch

ored

to

the

dru

m.

12.

Bef

ore

each

sh

ift,

ch

eck

th

e w

inch

for

wea

r or

dam

age.

C

hec

k

the

bra

kes

, w

ire

rop

e, h

ook

s, g

uid

es,

mou

nti

ng

bol

ts,

etc.

L

ift

a ca

pac

ity

load

or

a n

ear

cap

acit

y lo

ad a

few

in

ches

off

th

e fl

oor

and

ch

eck

th

e ab

ilit

y of

th

e b

rak

ing

syst

em t

o st

op a

nd

hol

d t

he

load

wit

hou

t ex

cess

ive

dri

ft, i

f th

e w

inch

is b

ein

g u

sed

for

lift

ing.

13

. N

ever

op

erat

e a

win

ch w

ith

a t

wis

ted

, k

ink

ed o

r d

amag

ed w

ire

rop

e.

14.

Per

iod

ical

ly i

nsp

ect

the

win

ch t

hor

ough

ly a

nd

rep

lace

wor

n o

r d

amag

ed p

arts

. K

eep

acc

ura

te r

ecor

ds

of a

ll i

nsp

ecti

ons

and

re

pai

rs.

15.

Fol

low

th

e lu

bri

cati

on

inst

ruct

ion

s p

rovi

ded

b

y th

e m

anu

fact

ure

r.

16.

Do

not

att

emp

t to

rep

air

the

wir

e ro

pe

or h

ook

s.

Rep

lace

hoo

ks

wh

en t

her

e is

a 1

5% in

crea

se in

th

e th

roat

op

enin

g or

wh

en t

her

e is

a 1

0% b

end

as

show

n b

y in

spec

tion

rec

ord

s.

17.

Kee

p t

he

rop

e cl

ean

an

d w

ell

lub

rica

ted

. R

epla

ce w

ire

rop

e th

at

is f

raye

d.

18.

Eas

e th

e sl

ack

ou

t of

th

e w

ire

rop

e w

hen

sta

rtin

g.

Do

not

jer

k

the

win

ch.

19.

If t

he

dru

m i

s ex

pos

ed t

o p

erso

nn

el w

alk

way

s, p

lace

a g

uar

d

over

th

e d

rum

. 20

. D

o n

ot u

se y

our

han

ds

to g

uid

e th

e ro

pe

onto

th

e d

rum

wh

en

win

din

g in

th

e w

ire

rop

e.

21.

Be

cert

ain

th

ere

are

no

obje

cts

in t

he

way

of

the

load

or

hoo

k

wh

en o

per

atin

g th

e w

inch

. 22

. D

o n

ot

use

h

igh

er

air

pre

ssu

re

than

reco

mm

end

ed

by

the

man

ufa

ctu

rer.

23

. U

se c

omp

ress

ed a

ir c

aref

ull

y.

Be

sure

th

e h

ose

cou

pli

ngs

are

se

cure

, an

d m

ake

cert

ain

a s

afet

y ch

ain

is p

rovi

ded

to

avoi

d h

ose

wh

ip if

th

e co

up

lin

g fa

ils.

24

. W

ear

pro

per

cl

oth

ing

to

avoi

d

enta

ngl

emen

t in

ro

tati

ng

mac

hin

ery.

25

. B

e ce

rtai

n

the

air

sup

ply

is

sh

ut

off

bef

ore

per

form

ing

mai

nte

nan

ce o

n t

he

win

ch.

26.

Pro

per

ly s

ecu

re a

win

ch b

efor

e le

avin

g it

un

atte

nd

ed.

27.

Do

not

lea

ve a

loa

d s

usp

end

ed f

or a

ny

exte

nd

ed p

erio

d o

f ti

me.

N

ever

leav

e a

susp

end

ed lo

ad u

nat

ten

ded

. 28

. D

o n

ot a

llow

un

qu

alif

ied

per

son

nel

to

oper

ate

a w

inch

. 29

. D

o n

ot o

per

ate

a w

inch

if y

ou a

re n

ot p

hys

ical

ly f

it t

o d

o so

. 30

. D

o n

ot d

iver

t yo

ur

atte

nti

on f

rom

th

e lo

ad w

hil

e op

erat

ing

a w

inch

. 31

. B

e ce

rtai

n t

he

load

is

pro

per

ly s

eate

d i

n t

he

sad

dle

of

the

hoo

k.

Do

not

tip

loa

d t

he

hoo

k a

s th

is l

ead

s to

sp

read

ing

and

eve

ntu

al

fail

ure

of

the

hoo

k.

32.

Do

not

for

ce a

hoo

k in

to p

lace

by

ham

mer

ing.

33

. N

ever

op

erat

e a

win

ch b

eyon

d t

he

poi

nt

wh

ere

less

th

an f

our

wra

ps

of w

ire

rop

e re

mai

n o

n t

he

dru

m.

34.

Do

not

use

th

e w

ire

rop

e as

a g

rou

nd

for

wel

din

g.

Do

not

att

ach

a

wel

din

g el

ectr

ode

to a

win

ch o

r sl

ing.

35

. N

ever

op

erat

e a

win

ch t

hat

mak

es e

xces

sive

mec

han

ical

noi

se.

Rep

ort

the

pro

ble

m im

med

iate

ly.

WARNING LABELS SUPPLIED ON WINCH

These labels are also available from RAM Hoist and Hoist.

! W

AR

NIN

G

DO

NO

T O

PE

RA

TE

WIT

HO

UT

GU

AR

DS

IN

PL

AC

E!

FA

ILU

RE

TO

DO

SO

CO

UL

D

RE

SU

LT

IN

IN

JU

RY

.

! WARNING !Do not weld base while connected to

winch.

Remove the bolts holding the winch to

the base and take the winch off the base

prior to welding base on location.

Failure to do so may damage the winch

due to arcing.

THIS WINCH IS FOR PERSONNEL

HANDLING USE ONLY

MAXIMUM RATED LOAD

CAPACITY 330 POUNDS (150Kg)330 (1.5 KN)336

1.0 General Information 1.1 User Responsibility and Safety Precautions

This equipment will perform in conformity with the description thereof, contained in this manual, its accompanying labels and/or inserts when it is installed, operated, maintained and repaired according to the instructions provided. This equipment must be maintained properly. Deficient equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, we recommend that a telephone or written request for service be made to RAM Winch & Hoist. This equipment or any of its parts should not be altered without prior written approval of RAM Winch & Hoist. The user of this equipment shall have the sole responsibility for any malfunction that results from improper use, faulty maintenance, damage, improper repairs or alterations made by anyone other than RAM Winch & Hoist.

1.2 Introduction 1.2.1 Purpose The purpose of this manual is to provide installation, operating and maintenance instructions and

procedures for your RAM Winch & Hoist. 1.2.2 Model Number, Serial Number and Options This manual covers the hoist built by RAM Winch & Hoist for your particular unit. The model

number and serial number are listed on the nameplate attached to the unit. 1.2.3 Warranty See standard warranty certificate. 1.3 Equipment Description 1.3.1 Capabilities and Limitations The hoist is a air driven cable-handling unit, with an automatic band brake and a disc brake

designed for use in the marine or industrial environment. It is designed for handling personnel and utility use. The unit is to handle one (1) person only. The unit has a limited pull capacity as required by DNV, NPD and NORSOK.

1.3.2 Specification and Descriptive Data

Working Line Pull 336 lb. (1.5 kN)

Cable Capacity 250 ft. of 3/8” wire rope. Line Speed 0-90 feet per minute Construction All steel with steel or stainless steel hardware. Finish Sandblasted to near white metal. Primer coated with

inorganic zinc to 2-3 mils DFT. Top coated with a Carboline marine coating system.

Bearings Roller-type flange-mounted bearings. Drive System An air piston motor coupled to a planetary gear

reducer. Controls Air Joystick Controller. Braking System Automatic Brake (spring-applied-pressure released

brake band type) and disc brake internal to the gearbox.

!!WARNING!! Do not manually release the brake if a load is

suspended by the hoist! Performance Single layer manriding rating as indicated on the

hoist nameplate is the maximum allowable load and pressure setting.

2.0 Functional Description 2.1 Major Assemblies

The hoist consists of the following major assemblies:

2.2 System Descriptions This hoist is supplied with the following items and safety devices. The descriptions give an overview of the functions or operations. This section must be read and understood prior to installing and operating the hoist.

2.2.1 Brakes

The hoist is equipped with an automatic band brake, which acts on the hoist drum. The brake is spring set/pressure release, and if system pressure is lost, the brake will set.

When the joystick of the Payout/Retrieve Joystick Controller valve is released, it will spring to center and dump the brake release pressure. The initial release is at approximately 20 psi and full release is at approximately 40 psi. The unit does have freefall or freewheel capabilities during Emergency-lowering. Pressure is required to open the brake and can be throttled by the joystick control valve. In case of an emergency, the emergency stop button can be pushed and the loss of system pressure will cause the brake to set.

General Assembly 406931 Levelwind Assembly 406943 Levelwind Guard Assembly 406972 Basic Winch Assembly 406932 Automatic Brake Assembly 406958 Pressure Roller Assembly 406962 Drum Assembly 406938 Control Console Assembly 406940

2.2.2 Wire Rope (optional) If RAM supplies the rope, it will be 3/8” diameter 304 stainless steel 7 x 19 construction with wire rope core. The rated breaking strength of this rope is 12,000 pounds. The rope is fitted with a stainless steel swaged button, which is also rated for the breaking strength of the rope. If the customer selects to supply their own wire rope, RAM recommends the above as a minimum. Note: Particular attention needs to be given to the dimensions of the swaged button to permit proper installation on the rope drum.

See Wire Rope Installation Instructions.

2.2.3 Emergency Lowering

In the event of a air failure, the Catalina is equipped with the ability to lower a person suspended by the wire rope. Refer to Section 4.5 for a complete description of the Emergency Lowering Procedure

2.2.4 Maintaining Dead Wraps on Drum

Three wraps are wound on the drum after cable anchoring. A cable clamp, which covers the three wraps, is bolted in place. The levelwind has a physical stop collar, which prevents the rope travel from unwrapping past four dead wraps. The levelwind would stop and if the unit failed to shut off, it would start wrapping cable back on the drum. See Cable Installation Instructions.

2.2.5 Overload Protection of Hoist

The Catalina is designed to lift 336lbs (1.5 kn) and to limit the maximum amount of line pull that the hoist produces in a stall condition. The pneumatic circuit is equipped with redundant pressure reducing and pressure relieving valves that are pre-set at the factory to prevent the unit from exerting excessive line pull. Attempting to tamper or adjust valve settings within the circuit could cause damage to the machinery and/or injure the personnel riding the cable. NOTE: Only qualified technicians may perform adjustments.

2.2.6 Emergency Stops The Catalina incorporates two (2) emergency stop devices. The first emergency stop is a manual ball valve (Pressure) located on the front side of the control panel cabinet in the incoming air pressure supply line. This valve will shut off all the air supply to the unit and has no bypass. It must be manually opened or closed. The other emergency stop is a large red palm button Emergency Stop valve located on the control panel. The palm button is pulled to the “up” position for normal operation. In the event of an emergency, the palm button can be pushed down which will then close off the air supply and the loss of system pressure will cause the brake to set. To reset the emergency stop palm button, pull the small detent button on the side to allow the palm button to pop up.

NOTE: These following systems have possible pinch points. Keep hands or objects away from these areas during operation.

2.2.7 Slack Wire Detection and Safety Shutoff An automatic levelwind is standard on the Catalina and is equipped with a slack wire detection and a travel limit device (RAM P/N AG00152) built in. Refer to Levelwind Assembly drawing 406943.

The rope is routed up through the levelwind guide sheave and pushes the spring loaded slack wire lever and roller up to the operable position. If the line goes slack, the spring tension pulls the lever down causing the trip button to shift the Slack Limit valve to open and the control system to loose air pressure. This will stop the unit and set the brake.

The unit is equipped with a spring-loaded Override push button (see Pneumatic Schematic drawing 407028). This valve is normally open/push to close and has a flush button guard. This override button has to be used in conjunction with the manual Joystick Controller valve to operate the hoist in the override mode.

2.2.8 De-Rail Protection The Catalina operates on a single layer of wire rope in the same fashion as an overhead hoist in principle. The unit is equipped with a pressure roller on the drum, which helps keep the cable laying in the grooves. The levelwind is chain driven and the system is equipped with adjustable travel limit stops as well as limited levelwind travel, which prevent the rope from being able to travel past the next to last groove on the drum. The Travel Limit valves serve as the first safety mechanism and are adjusted to trip and stop the hoist if the levelwind travels too far. If the travel limit valves should fail, the levelwind will stop within the confines of the drum flanges but operation would continue.

2.2.9 Travel Limit Valve

The travel limit switch system is located over and just behind the levelwind system (see drawing 406943). The Travel Limit valve (RAM P/N AG00152), when tripped, will open and cause the control system to loose air pressure. This will stop the unit and set the brake. The travel extent upper and lower limits can be adjusted, and then locked into position by tightening the clamping bolt. For travel limit assembly see drawing 406943.

2.2.10 Speed Controls

The Joystick Controller valve located on the control panel of the hoist is manually operated and supplies metered air flow to allow variable speed control from “creep” to “full speed”. This valve contains a center locking collar which must be lifted to allow the valve to function.

2.2.11 Cable Shields

A cable shield is mounted behind the drum to keep the cable slack pushed out to the front of the hoist in forced slack conditions (see Drawing 407250). This shield is not intended to prevent missed wrapping if slack gets pushed back into the unit, but does keep the wire rope from getting a large loop in the back of the hoist. The proper shield is required based on the rope exit angle of 0 or 45. The shield must also be set properly to have about 1/16” clearance from the wire rope on the drum.

All the above covered items are standard on Model Number AML336AK “CATALINA” hoist. This unit is a component of the lifting system. The complete system as required by DNV, NPD, NORSOK or UK has many requirements which can only be supplied or accomplished by the end user.

3.0 Installation Instruction (See Safety Instructions, Guidelines and Hoist Operating Practices) 3.1 Site Selection The hoist should be installed in a location that meets the following requirements: Firm foundation that allows the unit to be welded or bolted down to withstand a

minimum of 5 times the rated line pull of the hoist. Accessibility for the operator. Protection from heavy falling objects. Near an adequate air supply source. As far as possible from the first turn sheave.

Out of the way of other operations. Line of sight with lifted load. 3.2 Handling Lifting the unit on the topside of the frame (via lifting eyes) will accommodate standard lifts.

The unit may also be lifted from under the base by a forklift.

WARNING

DO NOT LIFT HOIST BY CABLE DRUM OR BY WRAPPING A SLING AROUND THE UNIT. DAMAGE TO CABLE, GUARD, SAFETY MECHANISMS OR BRAKE ASSEMBLY MAY RESULT. 3.3 Installation Procedures 3.3.1 Welding / Bolt Down The unit is equipped with a swivel base, to be welded to the deck (see Drawing 407037). A qualified engineer must determine if the site location is acceptable.

Welding must be performed by a qualified welder and the proper welding processes must be used.

Do not weld on the base with the hoist attached as this may cause arcing in the hoist components.

WARNING

Extreme care should be taken to orient the center of the hoist drum to be centered in line with the first turning sheave. The length of the drum must also be perpendicular to this centerline (see figure 1).

If it is not properly aligned, cable-laying problems will occur, which could damage the rope or hoist. The minimum distance from the hoist to the first sheave is shown in figure 1 as well as the maximum fleet angle.

After the base is welded down, immediately clean and recoat all exposed metal surfaces to prevent rust. Once this is completed, the hoist can be bolted to the base. Use only the bolts supplied with this equipment. (If the bolts are lost or damaged,

replace them with identical RAM hardware (reference drawing 406931 Items 56, 55, 53 when ordering). Do not substitute fasteners with substandard or lesser grade. This could result in decreased load holding capability. Torque the bolts to the proper settings.

After the hoist is secured in place, the air supply lines may be connected to the unit. Refer to the pneumatic schematic drawing 407028. The Pressure, Drain and Tank line connection locations are marked on the hoist. Only connect to a clean, air supply source.

3.4 Requirements Prior to Start Up

Prior to performing the following preliminary check procedures, the air pressure supply must be turned off by closing the Pressure ball valve (reference drawing 406940 Item14) located on the front of the hoist (to insure that the drum cannot accidentally rotate or the brakes activate, which could result in serious injury. The gearbox is shipped full but must be checked prior to operation. Refer to the maintenance section (Section 5.0 B) of this manual for instructions. Check all the bolts or fasteners on the unit. It is possible for them to vibrate loose during transportation. Check to ensure that all the wrapping and packing material is removed prior to operation.

With the Pressure ball valve located on the hoist still in the OFF position, supply pressure to

that point and make sure there are no leaks. Check to see that the Emergency Stop button (with red palm button) located on the control

panel is in the “up” position.

Once the above items are completed, pressurize the hoist by slowly opening the Pressure ball valve located on the front of the control console (drawing 406940 Item 14).

The slack limit switch may be open or exhausting when the pressure comes up. If this happens, you will need to push the Override button on the control panel.

You may want to adjust the cam on the slack limit trip arm during this

phase of the checkout. This will allow you to operate without holding down the override button.

This system must be reconnected after checkout and rigging of cable. Once the air supply is on, there should be a pressure reading on the main supply pressure gauge. The hoist controls are now operable and movement of the control valve will

cause the brake to release and the hoist drum will rotate. Check lines and component connections for leaks and make repairs or adjustments if needed. The hoist may now be operated to verify proper operation. If there is wire rope on the hoist drum, care must be taken to prevent

damage to the rope, the hoist or personnel. Operate the unit only a small amount in both directions to verify function. To operate, you will have to lift the center lock on the control valve handle and move the handle slowly off center in the direction of desired operation.

Be sure all personnel involved, or in the immediate vicinity, are aware of the

intended operation. Once the above is complete and the unit is operating properly, you may proceed to the next step. If the unit did not perform properly, consult RAM Winch and Hoist

Engineering Department for assistance.

3.5 Wire Rope Installation

The next phase in installation will be to rig up the wire rope. If your hoist is supplied with the wire rope already spooled on the drum, you will need to check the anchor bolt to ensure that it is tight and the dead wrap clamp is in place and tight. If you are supplying the wire rope, it must be spooled on properly. The wire rope must meet the requirements as specified in 2.2.2 of this

manual. Review drawing 406938M sheet 2 to see how the rope is connected to the hoist drum. The following procedure must be performed by qualified personnel only. While performing any part of this procedure that requires the placement of

hands in the access opening or on the drum, it is mandatory to turn off the air supply by closing the Pressure ball valve.

Pay strict attention to safety, as there is a high degree of risk involved since the drum must be rotated to the access position. The button on the end of the rope must be placed through the keyhole and then pulled forward so the wire rope is in the slot and the button is captured under the drum wall. Place the locking bolt and locking tab in the keyhole and fasten. Tighten securely and insert the cotter pin through the bolt and roll the ends to capture the cotter pin. Watch for pinch points. You will be able to slide the levelwind assembly down to the end of the drum where the rope will begin spooling. It will be necessary to remove one of the rollers (see drawing 406943M item 9) to be able to route the cable button through the levelwind. The roller is removed by removing the nut and bolt. Once the button is fed from the top going down to the drum, the roller must be replaced. Pinch hazards are possible. Make sure everything is clear and then turn the air supply back on. The next step will require an operator and assistant with gloves to handle the

cable. This portion of the procedure should be done with caution, as the hoist will be winding cable on the drum. The gloved assistant must help hold and guide the cable. The risk of cuts or punctures from the wire rope is possible as well as entanglement.

The operator must pay strict attention to the assistant, the rope winding, and

speed of the hoist. The hoist must be controlled at a very slow and safe rate of speed. Do not allow other personnel to talk to or distract the operator or assistant during this operation.

Begin rotating the drum in the retrieve mode while the assistant keeps some tension pulled on the rope. Rotate the drum in the retrieve mode until you have about 8 to 10 wraps on the drum. Bring the drum around until the threaded hole where the clamp bolts on, is on top and accessible. Turn the air supply valve (Pressure) off to attach the dead wrap clamp as

illustrated in drawing 406938M. The plate (item 4) will go over the top of three (3) wraps of cable. The bolt should get a few drops of Locktite. Then install and torque down.

After clearing everything out of the way of the drum, turn the air supply back

on. Be alert, as the system will again be operable. Spool the rest of the required cable on the drum.

3.5.1 Rigging The next step is to rig the cable and the rest of the lifting system.

This is the responsibility of the owner, operator and/or installer. You must

refer to the regulations, practices and procedures applicable for proper rigging techniques.

3.6 Slack Limit Setting

Once the rigging is complete, you will be able to adjust and set the slack limit safety device. In order to set the slack limit, the cable must have enough weight or resistance to overcome the spring pull down force of the trip lever. This will keep the lever arm held up so it does not trip the switch. To adjust the slack limit setting, adjust the bolt on the bracket of the Slack Limit switch (see drawing 406943M item 43 and item 29) to the desired trip point. Do not adjust while unit is in motion. The wire rope will be moving and could

cause injury.

3.7 Travel Limit Adjustment The next adjustments to make will be travel limit stops (see drawing 406943M item 27). These limit stops react with or depress the plunger on item 29 (limit switch on drawing 406943M) to shut the hoist off. Loosen the set screw in the Travel Limit cam in order to move the cam to the desired position. Always set the stop to react a little early, as there may be a 1 to 2 seconds lag

time until the hoist comes to a complete stop. Do not set the stops while the hoist is in motion as this may result in injury.

The best method is to rotate the drum until the cable is to the uppermost desired travel. With the hoist stopped, slide the upper stop over to push the plunger in. While holding the stop at this position, tighten the cam. Remember to set slightly ahead so there is stopping time. It is necessary to test the stop by rotating the drum to move the carriage away from the stop. (Note: The Override button must be pushed in order to do this). Slowly run the unit to drive into the stop and check for proper trip point.

Pay close attention to the traveling end of the rope to prevent two-blocking.

Make sure the lower trip is done in the same manner at the other end of the drum.

Ensure that all guards and safety devices are on the hoist and securely fastened. The hoist should be operated up and down a few times to check all functions. If they are working properly, the hoist is ready for operation.

4.0 Operating Instructions The following descriptions cover the functional operation of the hoist controls only. It does not cover any operations performed using the hoist. It is the operator’s responsibility to understand all facets of the operation.

The operator must be physically capable and mentally alert. They must have good hearing, vision and depth perception. The operator must make sure all conditions are safe for operations. If the operator feels that anything is unsafe, or even questionable, do not proceed until properly evaluated or corrected.

4.1 Hoist Controls

This hoist is controlled by a manually operated Joystick Controller valve (see drawing 406940M Sht1 item 8). This valve controls the rotational speed and direction of the hoist drum. To operate the valve, lift up on the center lock mechanism and move the joystick off center. The direction of movement will determine the rotation of the hoist. When standing behind the hoist, push the joystick forward, which will cause the drum to rotate in the payout mode.

Pull the joystick towards the back to rotate the drum in retrieve mode. The amount of offset from center will determine the speed. Use smooth, controlled movements on the joystick to prevent jerky movement on the rope. To stop the unit, bring the joystick to the center position and release the latch.

4.2 Brakes

The hoist is also equipped with a disc brake internal in the gearbox. This brake is a secondary redundant unit to the automatic brake and both brakes are rated for full load capacity.

Do not begin operations with only one brake functioning. If one or both

brakes are not functioning properly, it will become dangerous to operate.

When the hoist is operated in either payout or retrieve (pay-in) mode, the band brake cylinder will receive a pressure signal and automatically release the brake. When the joystick is brought back to the center position, hydraulic pressure in the brake cylinder will be vented to tank and the brake will automatically set. It takes approximately 40 psi to completely release the band brake.

4.3 Emergency Stop

To stop the hoist in case of emergency, push down on the Emergency Stop palm button. When the button is depressed, pressure is directed back to the tank which will cause the hoist motor to shutdown (no pressure) and will also cause the automatic brakes to set. To reset the emergency stop, pull out on the small plunger detent located on the side of the E-Stop valve body. Once the emergency stop button is reset, the Main System Pressure gauge will again indicate full system pressure. The hoist is also equipped with a secondary emergency stop valve which can be used to shut down the hoist. This valve is a manually operated two way ball valve labeled “Pressure” located on the backside of the control console. When closed, this valve will cut off all the air supply to the unit and has no bypass.

4.4 Manual Override

The manual Override button on the control panel is used to temporarily override a slack limit condition or an over travel condition in order to rotate the drum.

The override is only to be used to allow temporary operation of the hoist in a

slow and cautious manner to assist in correction of the limit tripped. This is to be performed by a qualified operator only! Failure to do so could result in the person on the rope or rider to be injured.

This device must NOT be blocked off or locked down. This would

permanently disable the safety limits and make the hoist unsafe.

4.5 EMERGENCY LOWERING OPERATION PROCEDURE In the event of the hoist motor becoming inoperable, it may be necessary to lower a suspended rider by emergency lowering procedures. This will allow lowering only, and the operator must be thoroughly trained to use this procedure.

Step 1. Turn OFF the Emergency Shut Off ball valve located on the front side of the hoist.

WARNING!

THIS PROCEDURE SHOULD BE CONDUCTED BY A TRAINED

OPERATOR ONLY. FAILURE TO CONTROL THE LOAD PROPERLY

COULD CAUSE SEVERE INJURY OR DEATH!

EMERGENCY SHUTOFF

Step 2. Locate EMERGENCY LOWERING DISC BRAKE RELEASE lever, pull, and hold to release.

DO NOT JAM OR LOCK THE AUTO BRAKE RELEASE LEVER TO HOLD IT OPEN OR RELEASED. CONTROL IT BY HAND ONLY! !WARNING!

KEEP THE DESCEND RATE UNDER CONTROL AT ALL TIMES!

DO NOT COMPLETELY RELEASE YOUR

GRIP ON THE MANUAL CALIPER BRAKE!

Step 3. Locate PIPE LEVER, insert band brake handle, and pull up to lower load while maintaining controlled descent.

5.0 Maintenance Procedure Failure to perform the required periodic maintenance can cause damage to

the hoist or greatly reduce the life of the equipment components.

A. Lubrication The proper lubricants and time intervals should be maintained and are required to keep the hoist in good running condition. The recommended intervals are based on heavy operating conditions for 4-5 hours per day.

INTERVALS CHECK Daily Visual inspection of hoist

Brake actuator Pressure Bypass indicator on filter

First 100 hours of operation on new unit Drain and refill gearbox

Weekly or after usage Clean unit

Monthly Grease bearing Check gear reducer oil level

Yearly Drain and refill gearbox Replace Filter element

Recommended Lubricants

Grease EP1 Multipurpose Lithium-based grease -20° - 40° F EP2 Multipurpose Lithium-based grease 30° - 120° F Oil CITGO EP68 for gear reducer only

The recommended grade of oil or grease must be used at all times. The use of

other grades could result in loss of efficiency, temperature problems or possible damage to components. Always inspect removed oil for signs of internal wear, damage or contamination. If this is found, further inspection of the component will be necessary before placing the hoist back in service. Always use proper containers and disposal methods when draining lubricants.

B. Gearbox Lubrication

Do not place hands in unit to remove or install drain/fill caps until the Air Pressure ball valve located on the hoist is off. If the drum were to be

rotated, it could cause injury. To check level, have one port at the 3 O’clock position. The unit should be

filled to this level. Do not overfill above this level as it may damage the unit or reduce efficiency. To fill, the drum must be positioned so there is one plug at the 12 O’clock position and one at the 3 O’clock position. Fill using the top plug until the oil is level to the bottom of the side plug. Once full, replace caps and tighten to snug.

To drain, rotate the drum until one port is at the bottom 6 O’clock position.

Remove plug and drain oil into proper container.

C. Check filter per indicated intervals. Filter is equipped with visual indicators that will pop-up indicating the filter element needs to be changed.

D. Wire Rope The wire rope must be inspected per the recognized standards.

5.1 Frequent and Periodic Inspections Frequent and periodic inspections must be carried out on the hoist and all associated

equipment. The amount of service is a partial-determining factor in the frequency of inspections. The hoist should always be visually inspected prior to operating and during operations. If there is any indication of the hoist operating irregularly, rope not laying properly, brakes grabbing or creeping or any other signs of damage or malfunction, cease operation until the problem is corrected or inspected by trained personnel. Periodic Inspections: Normal to heavy use-Inspect semiannually Severe use- Inspect quarterly Always maintain inspection records and keep them current and on file. These records should include all inspections, repairs and maintenance performed on each individual unit. Inspection Items 1. Inspect all fasteners and retainers for torques, loose, missing or damaged.

Correct or replace as required. 2. Drum, frame and structural items. Check for cracks, corrosion, wear or damage. Correct or replace as

necessary. 3. Brakes Check to ensure load-holding capability of 125% of the rate load. Also

check for wear or damage of auto and manual brake and correct or replace as necessary.

4. Components Inspect for any wear, abnormal sounds, abnormal operation or evidence of

damage. It will be necessary in some cases to remove the component and disassemble to properly inspect, (i.e., gear reducer. If any evidence is found, repair or replace as required).

5. Labels and Tags Check for missing, damaged or illegible. Replace as required.

Units not in regular use must be completely inspected by qualified personnel prior to operation (units left idle for more than one (1) month).

APPENDICES

Drawings Drawing Number General Assembly 406931 Levelwind Assembly 406943 Levelwind Guard Assembly 406972 Basic Catalina Assembly 406932 Automatic Brake Assembly 406958 Pressure Roller Assembly 406962 Brake Actuator Assembly 406263 Cable Retainer Assembly 407250 Drum Assembly 406938 Control Console Assembly 406940 Air Schematic 407028 Basic Winch Assembly 407009 RAM Winch & Hoist Load Test Procedures Gearbox Assembly Illustrations and Instructions Miscellaneous Manufacturer Data Sheets

RAM AIR WINCH PARTS

When ordering parts, please have the model number and serial number for your unit. If possible, please supply us with the original purchase order number.

See the following pages for part ordering information.

Please call (281) 999-8665 or fax an order to (281) 999-8666.

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:

SURFACE FEATURES: MACHINED PARTS ONLY

T.I.R .005 PERPENDICULAR .015

FLATNESS .010 PARALLEL .015

1600X.X ±0.03X.XX ±0.015X.XXX ±0.005FRACTION ± 1/16

ON ALL MACHINEDSURFACES

DIMENSIONS:

BREAK ALL SHARP EDGES

UNLESS OTHERWISE SPECIFIED:ALL DIMENSIONS ARE IN INCHES

AND ALL TOLERANCES ARE AS STATED

3rd ANGLE PROJECTIONDO NOT SCALE

AML336AK

RS8920LBS.

-

EST. FINISHEDWEIGHT

ORIGINAL JOB NO.

MODEL NUMBERNEXT ASSEMBLY

ANGLES: ±0.5°

APVD:

M. WEHMEYER

R. RIOS

R. RIOS

10/17/2012

6/13/2012CKD:

M.S. KLEINDWN:

ENG:

10/17/2012

TITLE:

10/17/2012

GENERAL ASSEMBLY, ML336AK,0° WRTOA

SIZE:

AF00455

406931MSHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

NONE OF1

0

3

B

THIS DRAWING IS THE PROPERTY OF RAM ITC. THE DESIGN AND DATASHOWN INCLUDES PROPRIETARY INFORMATION THAT DESCRIBES RAM ITC. PRODUCTS. THE BORROWER BY RECEIPT AND RETENTION OF THE DRAWING AGREES, THAT EXCEPT AS EXPRESSLY AUTHORIZED IN WRITING BY RAM ITC., IT WILL (1) ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; (2)NOT LOAN, REPRODUCE, EXHIBIT ORDISTRIBUTE THE DRAWING OR ANY COPY OF THE DESIGN OR DATA SHOWN FOR USE BY ANY OTHER THAN RAM ITC., AND (3) UPON DEMAND RETURN THE DRAWING, ALL COPIES AND ALL MATERIAL COPIES THEREFROM.

.1 1/2 LOCKWASHER10AG72322-29

.0 NAMEPLATE, ROPE LIFT1AG72032-28

1.0 ROLLER CHAIN, 128 LINK1AG35790-27

53.1 AIR/ HYDRAULIC ACTUATOR1AG35630-26

.0 1/4-20 X 7/8 RIVET NUT2AG35466-25

.3 1/2 BEVELED WASHER8AG12791-24

.1 #1/4-20 X 1/2 THUMB SCREW 4AG00269-23

.1 1/4-20 X 3/4 THUMB SCREW2AG00158-22

.0 NAMEPLATE, MADE IN USA1AG00007-21

12.0 CABLE RETAINER ASSY, VERTICAL1AG0725040725020

3.8 LEVELWIND GUARD1AG0713340713319

.1 GUARD CLAMP2AG0706440706418

8.9 DRUM GUARD, TOP, LONG1AG0706040706017

1.7 ACTUATOR BRACKET1AG0702740702716

84.8 MODIFICATION TO ASSEMBLY, RISER BASE1AG0702640702615

4.7 LEVELWIND GUARD ASSEMBLY1AG0697240697214

51.3 ASSEMBLY, LEVELWIND, MECHANICAL1AG0694340694313

1331.6 ASSEMBLY, BASIC CATALINA ML336AK1AG0693240693212

.1 COVER PLATE, CHAIN CASE, LEVELWIND1AG0628840628811

11.1 ASSEMBLY, BRAKE ACTUATOR, HYDRAULIC OIL1AG0626340626310

1.2 SPROCKET, NO.35, 34T, SS1AG061464061469

.1 BRACKET, DRUM GUARD1AG030414030418

.1 NAME TAG - RAM AIR WINCH1AG012694012697

.0 -4 HOSE ASSEMBLY, 48" LG HOSE1FP00032406931-066



AG00669HYDRAULIC TUBING, 1/4 x .065 WALL, 18 1/2 IN LG1-406931-033

AG00669HYDRAULIC TUBING, 1/4 x .065 WALL, 4 IN LG1-406931-022

AG00669HYDRAULIC TUBING, 1/4 x .065 WALL, 6 IN LG1-406931-011

Parts List

WT (LBS)EXPANDED DESCRIPTIONDESCRIPTIONQTYPART NO.DRAW NO.ITEM

.0 1/4x1/4 x 11/16 KEYSTOCK1FQ90100-57

.2 1/2-13 HEX NUT 4FQ12301-56

.3 1/2-13 HEX NUT8FQ12257-55

.0 1/4-20 HEX NUT JAM2FQ12018-54

.1 1/2 LOCKWASHER 8FQ11202-53

.0 1/4 LOCKWASHER3FQ11015-52

.5 1/2-13 X 1-1/2 HHCS4FQ02052-51

1.3 1/2-13 X 2 HHCS8FQ02041-50

.9 1/2-13 X 2 HHCS6FQ02024-49

.2 1/4-20 X 3/4 HHCS10FQ00534-48

.1 1/4-20 X 1/2 HHCS5FQ00505-47

.0 1/4-20 X 1/4 SET SCREW1FQ00504-46

.0 #10-24 x3/8 BHCS2FQ00302-45

.0 STREET ELBOW,45°, -2 F NPT X -2 M NPT1FP50236-44

.2 FITTING, -4 TUBE X -2 M NPT4FP50076-43

.1 ELBOW, -4 COMPRESSION X -2 M NPT1FP50075-42

.0 BUSHING, REDUCER, -4 F NPT X -6 M NPT1FP50072-41

.1 STREET ELBOW, -2 F NPT X -2 M NPT3FP50047-40


.1 STREET TEE, -2 M NPT X -2 F NPT X -2 F NPT2FP50017-38

.1 ELBOW, -4 M JIC X -4 M NPT1FP01103-37

.7 CRIMP FITTING, -4 F JIC SWIVEL X -4 HOSE6FP01059-36

.0 FITTING, PUSHLOK, -4 F JIC SWIVEL X -4 HOSE1FP01039-35

.1 ELBOW, -4 M JIC X -4 M SAE ORB1FP01018-34

.2 ELBOW, -4 M JIC X -2 M NPT3FP01011-33

.0 HOSE ASSEMBLY, CAT-DBH-15 1/2 INCH1AG78694-32

.4 1/2-13 HEX NUT6AG78628-31

.0 NAME PLATE SCREW12AG73302-30

Parts List


REVISION HISTORYREV DESCRIPTION DATE ECN0 INITIAL RELEASE 10/21/2012 -NOTES:

TORQUE ALL FASTENERS ACCORDING TO RAM PROCESS SPECIFICATION PS-100013 WHERE APPLICABLE.

1.

APPLY LOCTITE 277 TO FASTENERS AS REQUIRED PER MANUFACTURERS INSTRUCTIONS.3.

REFER TO SCHEMATIC (DRAWING NUMBER ) FOR CIRCUIT CONNECTIONS.6. PNEUMATIC 4070285. HOSES AND TUBING MAY NOT BE SHOWN IN ASSEMBLY FOR CLARITY.

MATCH DRILL HOLES Ø.131 FOR ITEM (SCREW) AND TAGS.4. 30

2. HALF FILL TORQUE HUB WITH EP 68 GEAR OIL.

DETAIL ASCALE 1 / 4

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

3

REV:

NONE

0SCALE:

2

406931MAF00455 OF

SHT:


BSIZE:

PART NUMBER:

DWG NUMBER:


TITLE:

A 38

40 43

42

38

40

49 29 31493129

19

23

10

12

26

51 29 56

26

512956 51 29 56

41 3735

15

50 24 53 55

33

33

33

16

33

16

33

36

18 47 54 48

14

17

132

1

50 24 53 55

23

23

48

48 8

43

40

44

43

36

36

36

36

36

406931-06 PARKER 351TC/ST-4 FP01059 FP01059 AIR/HYD ACTUATOR BRAKE ACTUATOR -406931-05 PARKER 351TC/ST-4 FP01059 FP01059 PRESSURE GAUGE GEAR BOX -406931-04 PARKER 351TC/ST-4 FP01059 FP01059 AIR/HYD ACTUATOR PRESSURE GAUGE -

TABLE 1-HOSE ASSEMBLIES AND TUBE PART NUMBERS (SEE DWG BOM FOR LENGTHS)ITEM NO. HOSE/TUBE PART NO. CRIMP FITTING 1 P CRIMP FITTING 2 P CONNECTION 1 CONNECTION 2 CONNECTION 3

39

39

34

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

3

REV:

NONE

0SCALE:

3

406931MAF00455 OF

SHT:


BSIZE:

PART NUMBER:

DWG NUMBER:


TITLE:

27

45

45

14

4752

4752

47 52

22

22

11

5746

2830

7 30

21 30

20

24 50 53 55

15

9

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:




X.X ±0.03X.XX ±0.015X.XXX ±0.005FRACTION ± 1/16


DIMENSIONS:





LBS.EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

8/16/2012CKD:

M.S. KLEINDWN:

ENG:

TITLE:

ASSEMBLY, BASIC CATALINAML336AK

SIZE:

AG06932

406932SHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

OF1

0

1

B


.3GR 81/2-13 X 1-3/4 SHCS2FQ02004-15

.5316SS1/2-13 X 1-1/2 HHCS4FQ02052-14

.1316SS1/2 LOCKWASHER6FQ11205-13

930.1SEE DRAWINGASSEMBLY, BASIC WINCH 1AG0700940700912

270.3SEE DRAWINGASSEMBLY, CONTROL CONSOLE, ML336AK1AG0694040694011

.0VEGTABLE FIBER, 1/32THKGASKET, MOTOR, PISTON 1AG062804062809

73.2GLOBE 210 MOTORPISTON MOTOR MODIFICATION1I4000154062748

33.7ASTM A516 GR.70ADAPTER, PISTON MOTOR-GEARBOX1AG059564059567

.0SEE DRAWINGHOSE ASSY, Ø1" HOSE SWIVEL ENDS1AG31028406310-2810

.0SEE DRAWINGHOSE ASSY, Ø1/2 HOSE SWIVEL ENDS1AG10021405595-216





.0SEE DRWGASKET, GEARBOX (ML336A)1AG786034029781

Parts List


REVISION HISTORYREV DESCRIPTION DATE ECN0 INITIAL RELEASE NOTES:

THOROUGHLY COAT FRAME TIE BAR TO FRAME CONNECTIONS AND ASSOCIATED FASTENERS WITH MARINE GRADE NEVER-SEIZE.

2.


1.

APPLY LOCTITE 277 TO FASTENERS AS REQUIRED PER MANUFACTURERS INSTRUCTIONS.3.HALF FILL TORQUE HUB WITH AN SAE 80W-90 GEAR OIL MEETING THE SPECIFICATIONS OF API GL-5.

4.

REFER TO SCHEMATIC (DRAWING NUMBER ) FOR CIRCUIT CONNECTIONS.6. PNEUMATIC 4070285. HOSES NOT SHOWN IN ASSEMBLY FOR CLAIRITY.

11

8

15 13 9

12

12

11

PRELIMINARYNOT RELEASED

FOR REFERENCE ONLY

7 1

14 13

cclements

Rectangle

cclements

Rectangle

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:






DIMENSIONS:





ML336AK

RS8920LBS.

406932

EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

M.WEHMEYER

R. RIOS

R. RIOS

8/14/2012

8/13/2012CKD:

M.S. KLEINDWN:

ENG:

8/14/2012

TITLE:

8/14/2012

ASSEMBLY, CONTROL CONSOLE,ML336AK

SIZE:

AG06940

406940MSHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

1/5 OF1

0

3

B


.6 ELBOW, 3/4 F NPT X 3/4 F NPT1FP01106-34

.1 PUSHLOK FITTING, -4 M NPTF X -4 HOSE1FP01042-33

.1 ELBOW, -4 M JIC X -4 F JIC SWIVEL1FP01017-32

.0 ADAPTER, -4 M JIC X -2 M NPT1FP01006-31


.2 MUFFLER, SINTERED BRONZE, 3/8" NPT2AG78693-29

.2 1/2" NPT AIR BLEEDER VALVE2AG73264-28

.6 QUICK EXH. VALVE, 1/4NPT2AG70031-27

.3 PRESSURE GAUGE, 1-1/2", 1000 PSI1AG50149-26

.0 #4 LOCKWASHER3AG35804-25

.0 #4-40 X 1/2 SHCS 3AG35803-24

.4 5/16-18 X 3-1/16 U-BOLT ID 1-7/16 W/NUTS2AG35668-23

.0 1/8 X 1/2 POP RIVET8AG35481-22

.0 KIT, LEVER SEAL1AG07074-21

1.0 MANUAL SHUT OFF VALVE (3W2P) 150 PSI MAX.1AG04717-20

1.4 BALL VALVE, 2 WAY, 3/4" NPT1AG03320-19

.4 SHUTTLE VALVE, 1/4" NPT, 200 PSI1AG03315-18

.2 MUFFLER, 1/2" NPTM2AG01401-17

.4 NUPRO RELIEF VALVE1AG00221-16

.0 FLOW CONTROL VALVE, 1/8" NPT1AG00180-15

1.6 BALL VALVE, 3 WAY, 3/4" NPT1AG00149-14

.2 PUSH BUTTON, OPERATOR1AG00148-13

.2 2 WAY VALVE, N/O,1/8" NPT, 300 PSI1AG00146-12

3.7 POPPET VALVE, 1" NPT NORMALLY CLOSED1AG00144-11

.0 HOSE, Ø1/4" X 36" LG, PLASTIC1AG00017-10

.3 PLACARD, EMERGENCY LOWERING PROCEDURE1AG071214071219

17.7 THROTTLE VALVE ASS'Y (SPECIAL)1AG786314069618

7.5 CONTROL CONSOLE PANEL1AG069604069607

121.0 END FRAME, DRIVE SIDE, ML336AK1AG069414069416

39.1 CONTROLS CABINET, ML336AK1AG064664069595

.0 PANEL FUNCTION TAG, EMERGENCY SHUT-OFF1AG064544064544

10.1 RELIEF VALVE, 1" NPT1AG063064063063

.0 PANEL FUNCTION TAG, CLOSED1AG30474403047-42

.0 PANEL FUNCTION TAG, OPEN1AG30473403047-31

Parts List


CONTINUED ON SHEET 2

.0 5/16" FLATWASHER4FQ10205-82

.2 3/8-16 X 1-1/4 HHCS 3FQ00896 -81

.2 5/16-18 X 1-1/4 HHCS4FQ00760-80

.1 1/4-20 X 1 HHCS7FQ00535-79

.2 1/4-20 X 3/4 HHCS8FQ00534-78

.0 #10-32 X 1/2 HHCS2FQ00325-77

.0 1/8 X 3/8 POP RIVET18FQ00016-76

.1 FITTING, FEMALE RUN TEE, -4 M JIC X -2 F NPT X -4 M JIC1FP50235-75

.1 PRESTOLOK PLUS FITTING, -4 TUBE X -4 M NPTF2FP50128-74

.1 ELBOW, PUSHLOK SWIVEL, -4 TUBE X -4 M NPTF2FP50125-73

.2 ANCHOR COUPLING, -4 F NPT X 3/4-16 M STRAIGHT THD1FP50119-72

.2 PRESTOLOK, BRANCH TEE, -4 TUBE X -4 TUBE X -4 M NPT SWIVEL1FP50117-71

.1 PRESTOLOK, BRANCH TEE, -4 TUBE X -4 TUBE X -2 M NPT SWIVEL1FP50116-70

1.4 STREET ELBOW, -12 F NPT X -12 M NPT4FP50108-69



.0 PLUG, 1/4" NPT X C'SUNK HX1FP50084-66

.1 ELBOW, PUSHLOK SWIVEL, -4 TUBE X -2 M NPTF 2FP50082-65

.0 PUSHLOK STRAIGHT, 10-32 UNF MALE X 1/4" T, BRASS1FP50081-64




.1 LONG NIPPLE, 1/4 M NPT X 1-1/2 LG1FP50031-60


.2 FITTING, BRANCH TEE, -4 F NPT X -4 F NPT X -4 M NPT1FP50015-58

1.3 1" MPTX3/4"FPT BUSH 150 LB6FP50010-57

.2 CLOSE NIPPLE, 1 M NPT3FP19822-56

2.5 Street Elbow, 3/4" 150# GALV.4FP50003-55

.1 BUSHING, 1" MNPT X 1/2" FNPT, 150 LB, GALV1FP50002-54

3.4 STREET ELBOW, 1" 6FP50000-53

.1 BUSHING, 3/4 MPT X 1/4 FPT, 150LB, GALV1FP20199-52

.2 NIPPLE, 3/4 M NPT X 2 LG 1FP19772-51

.3 NIPPLE, 3/4 M NPT X 3 LG1FP19760-50

.1 LONG NIPPLE, 1/4 M NPT X 4 LG1FP19699-49

.0 CLOSE NIPPLE, 1/4 M NPT1FP19695-48

.2 COUPLING, FEMALE, 1/2", 150LB, GALV1FP15107-47

.8 TEE, 1" FPT, 150LB1FP13601-46

.5 TEE, 3/4" FPT, 150LB, GALV1FP13345-45

.5 STREET TEE, -4 M NPT X -4 F NPT X -4 F NPT3FP12080-44

1.1 ELBOW, 45° 1NPT, CLASS 1502FP10917-43



.0 BUSHING, 1/4 MPT X 1/8 FPT, 150LB, GALV1FP10439-40




2.6 ADAPTER, -12 M JIC X -12 M NPT7FP01345-36


Parts List



APPLY LOCTITE 277 TO FASTENERS AS REQUIRED PER MANUFACTURERS INSTRUCTIONS.1.TORQUE ALL FASTENERS ACCORDING TO RAM PROCESS SPECIFICATION PS-100013 WHERE APPLICABLE.

2.

REFER TO SCHEMATIC (DRAWING NUMBER ) FOR CIRCUIT CONNECTIONS.3. PNEUMATIC 407028

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

3

REV:

1/5

0SCALE:

2

406940M

AG06940 OFSHT:


BSIZE:

PART NUMBER:

DWG NUMBER:


TITLE:

2.3 MOUNTING BRACKET, 1 IN FITTINGS2LB50031-94

11.7 PRESSURE REGULATOR/GAUGE1LB00013-93

14.4 LUBRICATOR UNIT, 1" NPT1LB00012-92

9.8 FILTER UNIT, 1" NPT1LB00009-91

1.0 1" NPT SILENCER2LB00001-90

.0 #4-40 HEX NUT3FQ35740-89

.1 3/8-16 HEX NUT NYLOK3FQ12157-88

.0 5/16-18 HEX NUT4FQ12125-87

.1 1/4-20 HEX NUT15FQ12015-86



.0 #10 LOCKWASHER2FQ11001-83

.0 5/16" FLATWASHER4FQ10205-82

Parts List


922

8

78 84 86

21 76

13

2066

26242589

476

1

19

276

7783

61

11

9362

7474

32

55

57

36

15

40

52

45

36

19

55

90

53

233

30

65 2873

55

14

50

6

5

5

6

41

55

91

16 37 67

4717

57

36

43

4638

69

17

69

53

53

7318

44

81 88

6620

2927

33

44

28

44

49

62

72 59

SECTION A-ASCALE 1 / 8

DETAIL CSCALE 1 / 5

SECTION B-BSCALE 1 / 8

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

3

REV:

1/5

0SCALE:

3

406940M

AG06940 OFSHT:


BSIZE:

PART NUMBER:

DWG NUMBER:


TITLE:

A

A

C

B

B

36

838

69

56

57 36

87 85 80 82

94

91

29

27

73

3

92

31

12

93

5720

93

73

6518

74

4428

49

62

35

68

69

695134

36

49

64

55 36

53

90

3

23

57

5555

14

76

3163

12

13

93

61

3

6555

19

45

36

2773

60

92

80 87

80 82 85 87

79 84 86

80

57

55

41

91

53

54

8

69

69

46

17

38

67 37

39

42

56

75

32

29

2733

44

28

62

70

55

71

70

58

74

43

5862

62

65

53

90

53

72 59

72

59

48

36

69

53 57

53 54 35

69

6817

1234

B

A

4 3 2 1

A

B

REV DESCRIPTION DATE ECN#


AND ALL TOLERANCES ARE AS STATEDANGLES: SURFACE FINISH:

125




FLATNESS 0.010 PARALLEL .015

DWN:

CKD:

ENG:

APVD:

M.S. KLEIN

W. CUBERTSON

M. WEHMEYER

M. WEHMEYER

6/30/2010

1/12/2010

1/12/2010

1/12/2010

THIS DRAWING IS THE PROPERTY OF RAM ITC. THE DESIGN AND DATA SHOWN INCLUDES PROPRIETARY INFORMATION THAT DESCRIBES RAM ITC. PRODUCTS. THE BORROWER BY RECEIPT AND RETENTION OF THE DRAWING AGREES, THAT EXCEPT AS EXPRESSLY AUTHORIZED IN WRITING BY RAM ITC., IT WILL (1) ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; (2) NOT LOAN, REPRODUCE,

EXHIBIT OR DISTRIBUTE THE DRAWING OR ANY COPY OF THE DESIGN OR DATA SHOWN FOR USE BY OTHER THAN RAM ITC., AND (3) UPON DEMAND RETURN THE DRAWING, ALL COPIES AND ALL MATERIAL COPIES THEREFROM.

EST. FINISHED WT.

ACTUAL WT.

ORIGINAL JOB NO:

LBS

LBS

11-

RS7985

SIZE: B DWG NUMBER: REV:

SH:SCALE:PT/NO:

TITLE: ASSEMBLY, BRAKE ACTUATOR,HYDRAULIC OIL

406263MAG06263

3rd ANGLE PROJECTION

FULL

1

ON ALLMACHINEDSURFACES

0.5° DIMENSIONS:

X.XX.XXX.XXX

FRACTION

±0.06±0.015±0.005±1/16

NEXT ASSEMBLY MODEL NO.

14603 CHRISMANHOUSTON, TX 77039

1 OF 1

405975

HML336A-250-38

.0 LONG NIPPLE, 1/8 x 1 1/21FP50078-15

2.9 REMOTE ACTUATOR, HYDRAULIC, 316SS1AG35629-14

.0 KNOB, BALL Ø1-1/2" 1AG78718-13

.3 1/2-13 X 1-1/2 HHCS2FQ02052-12

.3 5/16-20, U-BOLT FOR 2in OD2AG78716-11

.0 1/2" LOCKWASHER2FQ11205-10

.1 1/2-13 HEX NUT 2FQ12250-9

.0 1/2-20 HEX NUT 1FQ02136-8

.0 90 DEG. STREET ELBOW, 1/8" NPT, BRASS1FP50047-7

.1 CLEVIS PIN, Ø5/16x1 3/8LG2AG78719-6

.0 1/8 x 1 COTTER PIN2FQ00020-5

.4 FLUID RESERVOIR, ALUM1AG35584-4

5.5 MTG BRACKET, BRAKE ACTUATOR1AG035784035783

.7 CLEVIS, BRAKE ACTUATOR1AG035824035822

.8 LEVER, BRAKE ACTUATOR1AG035834035831

Parts List

WT (LBS)EXPANDED DESCRIPTIONDESCRIPTIONQTYPART NODRAW NO.ITEM

1

12109

8

5

2

6

117

15

4

14

3

13

0 INITIAL RELEASE 1/12/2010 -NOTES:1. ASSEMBLE COMPONENTS AS SHOWN.2. USE ONLY MINERAL BASED HYDRAULIC OIL IN RESERVOIR (ITEM 4) AND REMOTE ACTUATOR (ITEM 14).

1 CHANGED FITTINGS FOR RESERVOIR, REMOVED OUTPUT FITTING 1/4/2011 2245

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:






DIMENSIONS:





ML336AK

RS8913LBS.

407000

EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

M. WEHMEYER

R. RIOS

R. RIOS

10/10/2012

6/12/2012CKD:

M.S. KLEINDWN:

ENG:

10/10/2012

TITLE:

10/10/2012

ASSEMBLY, BASIC WINCH

SIZE:

AG07009

407009MSHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

NONE OF1

0

2

B


.3 1/2-13 HEX NUT NYLOK6FQ12251-25

.2 1/2-13 HEX NUT 4FQ12250-24



.1 1/2 FLAT WASHER8FQ10355-21

.2 1/2-13 X 1-1/4 HHCS2FQ02044-20

.6 1/2-13 X 1-3/4 LG SQNECK RNDHD4FQ02043-19

.0 1/4-20 X 1 HHCS1FQ00535-18

.1 1/4-20 X 3/4 HHCS5FQ00534-17

.0 1/4-20 X 5/8 HHCS2FQ00511-16

.0 1/8 NPT 90deg Zerk1AG73189-15

.1 NIPPLE, 1/8NPT x 4 1/2 L1AG50136-14

.0 HEX COUPLING, 1/8 NPT1AG50135-13

.0 1/4-20 X 7/8 RIVET NUT4AG35466-12

.7 FLANGE BEARING, MODIFIED1AG4803640721811

10.9 DRUM GUARD, BACK, SHORT, RIVETED1AG0703440703410

11.6 PRESSURE ROLLER ASSEMBLY1AG069624069629

31.9 AUTOMATIC BRAKE ASSEMBLY1AG069584069588

100.3 END FRAME, BEARING SIDE, ML336AK1AG069424069427

741.3 ASSEMBLY, DRUM1AG069384069386

2.5 LEVER, BRAKE RELEASE1AG030884030885

6.5 DRUM GUARD, FRONT1AG786424029894

2.0 COVER, BRAKE CALIPER1AG029324029323

5.1 SLIDE BAR, LEVELWIND1AG786104029222

15.5 TIE BAR3AG786054029211

Parts List



4

10

7

8

6

6

9

5

17 12


1.

APPLY LOCTITE 277 TO FASTENERS AS REQUIRED PER MANUFACTURERS INSTRUCTIONS.3.THOROUGHLY COAT FRAME TIE BAR TO FRAME CONNECTIONS AND ASSOCIATED FASTENERS WITH MARINE GRADE NEVER-SEIZE.

4.

2. HALF FILL TORQUE HUB WITH EP 68 GEAR OIL.

SECTION A-A

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

2

REV:

NONE

0SCALE:

2

407009MAG07009 OF

SHT:

ASSEMBLY, BASIC WINCH

BSIZE:

PART NUMBER:

DWG NUMBER:


TITLE:

A

A

1

2521

1

2521

9

7

9

31622

18

5

10

17

4

24 23 19

6

6

8

1712

19

172216

17

22

15

13

14

2

11

2021

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:






DIMENSIONS:





ML336AK

LBS.EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

M. WEHMEYER

R. RIOS

E. SOESANTO

4/2/2012

4/2/2012CKD:

R. RIOSDWN:

ENG:

4/2/2012

TITLE:

4/2/2012

ASSEMBLY, LEVELWIND,MECHANICAL

SIZE:

AG06943

406943MSHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

1:4 OF1

0

2

B


63 - FQ00036 1 #10-24 X 1/2 SET SCREW CUP .0

62 - FQ00307 3 1/4-28 X 1/4 SET SCREW FLAT PT. .0

61 - FQ12157 2 3/8-16 HEX NUT NYLOK .1

60 - FQ12156 1 3/8-16 HEX NUT NYLOK .0

59 - FQ12006 2 #10-32 HEX NUT .0

58 - FQ11001 4 #10 LOCKWASHER .0

57 - FQ10547 1 1 FLAT WASHER NARROW .0

56 - FQ10255 2 3/8 FLAT WASHER .0

55 - FQ12015 2 1/4-20 HEX NUT .0

54 - FQ10155 3 1/4 FLAT WASHER .0

53 - FQ02144 1 3/8-16 X 1-3/4 SHCS SHOULDER .2

52 - FQ00935 1 3/8-16 X 3-1/2 HHCS .1

51 - FQ00504 1 1/4-20 X 1/4 SET SCREW .0

50 - FQ00317 8 #10-24 X 5/8 SHCS .1

49 - FQ00299 4 #10-24 X 1 HHCS .0

48 - FQ00234 5 #10-24 X 1/4 SHCS SHOULDER .1

47 - FQ00232 10 #10 LOCKWASHER .0

46 - FQ00231 6 #10 FLAT WASHER .0

45 - FQ00215 2 #8-32 X 7/16 FHPH SCREW, 82° .0

44 - FQ00037 1 KEYSTOCK, SQUARE, 3/16 x 3/16 x 3/4 .0

43 - FQ00306 2 1/4-20 X 1 SHCS FULL THREAD 316SS .0

42 - AG35782 2 FLANGE BEARING, Ø3/8 X Ø5/8 X 3/4 LG. .0

41 - AG35778 1 TORSION SPRING, 3/8 IN. SHAFT .0

40 - AG35781 2 COMPACT COMPRESSION SPRING .1

39 - AG35784 2 CAM ROLLER .1

38 - AG35783 1 SLEEVE BEARING, Ø1-1/4 X 1-1/2 LG. .0

37 - AG73188 1 1/8 PTF ST ZERK, SHORT .0

36 - AG35685 1 SNAP SPRING, EXTERNAL 16mm .0

35 - AG35684 2 SNAP SPRING, INTERNAL 35mm .0

34 - AG35683 2 BEARING, BALL, .669IN X 1.378IN X .394IN .2

33 - AG35645 1 TORSION SPRING, LEFT, 1.348 O.D. X 0.115 WIRE, SS .1

32 - AG35644 1 TORSION SPRING, RIGHT, 1.348 O.D. X 0.115 WIRE, SS .1

31 - AG35642 2 ROD WIPER 1IN. X 1.125 IN. X 0.125 NITRILE .0

30 - AG35639 2 BUSHING, 1 ID x 1.125 OD x 1 L .0

29 - AG00152 2 2 WAY VALVE, N/C,1/8" NPT, 300 PSI .4

28 406986 AG06986 1 TRAVEL LIMIT SHAFT COLLAR .0

27 406984 AG06984 2 TRAVEL LIMIT CAM .2

26 406983 AG06983 1 SLACK LINE ROLLER SHAFT 1.4

25 406982 AG06982 2 SLACK LINE PIVOT ARM 1.3

24 406981 AG06981 1 LEVELWIND CARRIAGE SPACER .1

23 406978 AG06978 1 MACHINING, LEAD SCREW NUT RETAINER .5

22 406977 AG06977 1 MACHINING, LEAD SCREW NUT .7

21 406975 AG06975 1 MACHINING, LEVELWIND CARRIAGE 6.6

20 406956 AG06956 1 TRAVEL LIMIT CAM BRACKET .1

19 406955 AG06955 1 SLACK LINE LIMIT SWITCH BRACKET .1

18 406954 AG06954 1 TRAVEL LIMIT SWITCH BRACKET .1

17 406953 AG06953 1 SLACK LINE CAM BRACKET .1

16 406952 AG06952 1 TRAVEL LIMIT SHAFT 1.2

15 406950 AG06950 1 MACHINING, LEAD SCREW 6.4

14 406945 AG06945 1 MACHINING, LEVELWIND MOUNTING PLATE, NON-DRIVE SIDE 10.0

13 406944 AG06944 1 LEVELWIND MOUNTING PLATE, DRIVE END 10.5

12 406393 AG16393 1 SPACER, LEVELWIND SHAFT .0

11 406386 AG06386 1 SPROCKET, NO.35, 17T, SS .4

10 406985 AG06985 1 TRAVEL LIMIT CAM STOP BRACKET .1

9 406218 AG06218 1 ROLLER, ROPE KEEPER .0

8 406195 AG06195 1 TRAVEL LIMIT RAMP .1

7 406194 AG06194 1 ROLLER, SLACK LINE .7

6 406182 AG06182 2 THRUST WASHER, FLEETING SHEAVE .1

5 406181 AG06181 2 BUSHING, SLACK LINE PIVOT ARM .0

4 406180 AG06180 2 BUSHING, FLEETING SHEAVE .0

3 406155 AG06155 1 MACHINING, SHEAVE CARRIAGE .6

2 406141 AG06141 1 MACHINING, FLEETING SHEAVE, MODIFIED 2.8

1 406140 AG06140 1 MACHINING, GUIDE SHAFT 5.3

Parts List

ITEM DRAW NO. PART NO. QTY DESCRIPTION EXPANDED DESCRIPTION WT (LBS)

REVISION HISTORYREV DESCRIPTION DATE ECN0 INITIAL RELEASE 4/2/2012 -

1.

DETAIL ASCALE 1 / 2 DETAIL B

SCALE 1 / 2

SECTION C-CSCALE 1 / 4

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

2

REV:

1:4

0SCALE:

2

406943MAG06943 OF

SHT:

ASSEMBLY, LEVELWIND,MECHANICAL

BSIZE:

PART NUMBER:

DWG NUMBER:


TITLE:

A B

C C

14

25

3435

12

364057

34

35

40

51

44

11

24

43

55

29

19

395947545454

10

50 47

43 55

20 3948

4153

43

55

17

50

47

46 25

41

42 28

42

23

495838

21 37

15

26

61 7 61

52565660

9

11

445

48

33

131314

27

62

27

62

42

28

16

42

42

53

32

48

24

6

3

31

30

21

42

48

25

8

45

18

50

47

46

22

63

11

29

NOTES:1. THIS IS THE TRAVEL LIMIT SWITCH.

2.

1.

2. THIS IS THE SLACK LINE LIMIT SWITCH.

292.

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:




4.9X.X ±0.03X.XX ±0.015X.XXX ±0.005FRACTION ± 1/16


DIMENSIONS:





ML336PAK

RS8920LBS.

406931

EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

M. WEHMEYER

R. RIOS

R. RIOS

5/1/2012

5/1/2012CKD:

M.S. KLEINDWN:

ENG:

5/1/2012

TITLE:

5/1/2012

LEVELWIND GUARD ASSEMBLY

SIZE:

AG06972

406972MSHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

NTS OF1

1

1

B


.0 #8 X 1/2 SHEET METAL CROSS RECESS8FQ00227-3

2.9 CHAIN GUARD, LEVELWIND1AG069734069731

1.7 BACKING PLATE, LEVELWIND1AG069744069742

Parts List


REVISION HISTORYREV DESCRIPTION DATE ECN0 INITIAL RELEASE 5/1/2012 -1 CHANGED MOUNTING TAB CONFIGURATION 9/13/2012 2545

NOTES:

2

1

3

ALIGN ITEM 1 AND 2 AS SHOWNDRILL 8 PILOT HOLES FOR #8

SELF TAPPING SCREWSTHEN DRILL CLEARANCE HOLES

IN ITEM 1 ONLY

6 3/8

5/16

12 3/4

ITEM 1 AND ITEM 2FLUSH ON THIS FACE

(2)

5/16

(24 5/16)

5/16

REMOVE ALL BURRS AND BREAK SHARP EDGES AND CORNERS.1.

3. SHEET METAL SHOP TO SUPPLY ASSEMBLED WITH FASTENERS AS SHOWN.

2. ALIGN ITEM 1 AND ITEM 2 SO THAT THE PIECES ARE FLUSH AS SHOWN AND MATCH DRILL EACHPIECE AS SHOWN.

(6 1/4)

(.38 THRU TYP)

SECTION A-ASCALE 1 / 8

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:






DIMENSIONS:





ML336AK

RS8913LBS.

407009

EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

M. WEHMEYER

R. RIOS

R. RIOS

8/14/2012

8/14/2012CKD:

M.S. KLEINDWN:

ENG:

8/14/2012

TITLE:

8/14/2012

ASSEMBLY, DRUM

SIZE:

AG06938

406938SHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

1/8 OF1

2

2

B



110.0 GEARBOX, WITH INTERNAL BRAKE1AH00332-6

.2 5/8 LOCKWASHER HI-COLLAR9FQ11253-5

2.3 5/8-11 X 1-3/4 SHCS9FQ12743-4

1.3 5/8-11 X 1-1/2 HHCS 6FQ12741-3

1.0 HOSE ASSEMBLY2AG030754030752

625.0 LEFT HAND GROOVE DRUM, FLANGE/WEDGE1AG070774070771

Parts List


BB

A

A

REVISION HISTORYREV DESCRIPTION DATE ECN0 INITIAL RELEASE 8/14/2012 -1 CHANGED ROPE RETAINING LOCKING CONFIGURATION 10/8/2012 25362 REPLACED DRUM 8/14/2012 2566

NOTES:


1.


HALF FILL TORQUE HUB WITH AN SAE 80W-90 GEAR OIL MEETING THE SPECIFICATIONS OF API GL-5.

4.

3. INSTALL (ITEM 1) OIL LINE PRIOR TO INSTALLING (ITEM 9) GEARBOX AND INSURE OIL LINES DO NOT KINK OR ARE DAMAGED AT INSTALLATION OF GEARBOX.

5. FOR FILLING OF DRUM ONE OF THE OIL LINES MUST BE IN THE HORIZONTAL AND ONE IN THE DOWN POSITION, FOR DRAINING ONE LINE HORIZONTAL AND ONE LINE UP.

6. USE TORQUE VALUE OF 88 FT-LBS FOR THE 5/8-11 SHCS, DO NOT OVER TORQUE BOLTS.

37

1

25

SECTION B-BSCALE 1 / 4

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

2

REV:

1/8

2SCALE:

2

406938AG06938 OF

SHT:

ASSEMBLY, DRUM

BSIZE:

PART NUMBER:

DWG NUMBER:


TITLE:

37

6

6

6 45

456

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:






DIMENSIONS:





ML336AK

RS8913LBS.

407000

EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

M. WEHMEYER

R. RIOS

R. RIOS

10/5/2012

10/5/2012CKD:

M.S. KLEINDWN:

ENG:

10/5/2012

TITLE:

10/5/2012

CABLE RETAINER ASSY, VERTICAL

SIZE:

AG07250

407250MSHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

1/4 OF1

0

1

B


.1 3/8-16 HEX NUT4FQ12155-10

.1 1/4-20 HEX NUT8FQ12015-9



.0 3/8 FLAT WASHER4FQ10255-6

.2 3/8-16 X 1-1/4 HHCS 4FQ00896 -5

.1 1/4-20 x 3/4 HHCS8FQ00525-4

10.3 WELDMENT, CABLE RETAINER PLATE, VERTICAL PAYOUT1AG072494072493

.5 MOUNTING CLIP BRG SIDE2AG072484072482

.6 MOUNTING CLIP DRIVE SIDE2AG072474072471

Parts List



3

4 7 9

5 6 8 10

479

4794 7 9

56810

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:






DIMENSIONS:





ML336AK

RS8913LBS.

407009

EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

M. WEHMEYER

R. RIOS

R. RIOS

5/16/2012

5/16/2012CKD:

M.S. KLEINDWN:

ENG:

5/16/2012

TITLE:

5/16/2012

AUTOMATIC BRAKE ASSEMBLY

SIZE:

AG06958

406958MSHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

NTS OF1

1

1

B


.0 1/2-13 HEX NUT NYLOK1FQ12251-21

.0 MUFFLER, 1/4"NPT1AG78690-20

.1 BUSHING, 11/16OD X 5/8ID X 2LG2AG78635-19

.0 1/2 X 1-1/2 SPRING PIN1AG78634-18

.0 1/8 X 1 COTTER PIN6AG78630-17

.1 1/2 LOCKWASHER6AG78629-16

.4 1/2-13 HEX NUT6AG78628-15

1.0 1/2-13 X 1-3/4 HHCS6AG78627-14

.9 ROD CLEVIS, NUT & PIN1AG78617-13

.2 BRAKE ADJUSTING SCREW1AG0723940723912

4.7 BAND BRAKE BRACKET1AG0695740695711

.1 CLEVIS PIN, 1/2 X 2.67 1AG30394403039-0410

.1 CLEVIS PIN, 1/2 X 2.14 1AG30393403039-039

.1 CLEVIS PIN, 1/2 X 1.94 1AG30392403039-028

8.1 AIR CYLINDER ASSEMBLY1AG786224030067

1.2 WELDMENT, BRAKE YOKE1AG786244029676

1.0 BAND BRAKE PIN2AG786064029375

2.4 AUTO BRAKE LEVER1AG786184029274

2.5 CYCLINDER BRACKET1AG786264029253

3.5 SHORT BRAKE BAND ASSEMBLY1AG730524005652

5.4 LONG BRAKE BAND ASSEMBLY1AG730534005601

Parts List


REVISION HISTORYREV DESCRIPTION DATE ECN0 INITIAL RELEASE 5/17/2012 -1 CHANGED BRAKE ADJUSTING SCREW 10/21/2012 2540

NOTES:

8 171017 6 1221

(14 9/16)

18

141516

14 15 16

5 19

13

20

7

111

2

4

917

3

14 REF.

8 171017 6 1221

REMOVE ALL BURRS AND BREAK SHARP EDGES AND CORNERS.1.TORQUE ALL FASTENERS ACCORDING TO RAM PROCESS SPECIFICATION PS-100013 WHERE APPLICABLE.

2.

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

125

SURFACEFINISH:






DIMENSIONS:





ML336AK

RS8913LBS.

407009

EST. FINISHEDWEIGHT

ORIGINAL JOB NO.


ANGLES: ±0.5°

APVD:

M. WEHMEYER

R. RIOS

R. RIOS

5/16/2012

5/16/2012CKD:

M.S. KLEINDWN:

ENG:

5/16/2012

TITLE:

5/16/2012

PRESSURE ROLLER ASSEMBLY

SIZE:

AG06962

406962SHT:SCALE:

DWG NUMBER: REV:

PART NUMBER:

1/2 OF1

0

1

B


.0316SS1/4 LOCKWASHER2FQ11015-10

.218-8SS3/8-16 X 3/4 SHCS SHOULDER2FQ02141-9

.2GR 5, PLT3/8-16 X 1/2 SHCS SHOULDER2FQ02140-8

.0316SS1/4-20 X 3/4 HHCS2FQ00534-7

.3316SS, ASSOCIATED SPRINGSPRING EXTENSION, Ø1x .125 WIRE Ø, 3.5 FREE LG2AG35788-6

.2SOFT BRASS1 FLAT WASHER THRUST2AG35381-5

.4MMC, 6436K38 SPLIT COLLAR, 1 3/4 OD x 1 BORE2AG12177-4

4.1NYLONPRESSURE ROLLER, Ø3 IN1AG069634069633

.5316SSCOVER, SPRING1AG029734029732

5.6-SHAFT, ROLLER1AG029724029721

Parts List


REVISION HISTORYREV DESCRIPTION DATE ECN0 INITIAL RELEASE 5/16/2012 NOTES:

9

6

8

7 10

92

710

1

3

45

5

4


(4 7/8)

COMPONENT DATA

RAM WINCH P/N AH00332 GEARBOX

SPINDLE BRAKE DISASSEMBLY & ASSEMBLY

This section applies to servicing the Spindle-Brake assembly. This procedure does not require removing the gearbox from the winch. RAM WINCH strongly suggests requesting advice from RAM service department at 281-999-8665 prior to removing the gearbox.

11

7HB(A, B, C, D, E, X) SPINDLE-BRAKE DISASSEMBLY

NOTE: This procedure applies only to units with integral Input Brake (8).

CAUTION: Eye protection must be worn while performing the steps 1-3 in this procedure.

1. Compress the Compression Springs (8L) by installing two 1/4-20 x 5/8” Flat Head Cap

Screws (22) through Pressure Plate (8B) and into Piston (8A) and tightening incrementally until spring force has been taken off of the Retaining Ring (8C).

NOTE: Flat Head Cap Screws (22) are removed prior to shipping new units since they are for transit and service only. They are included in most brake repair kits. See details in Brake Service Kit section (p. ??)

2. Using retaining ring pliers, remove Retaining Ring (8C) from the groove in the Spindle (1A).

cclements

Rectangle

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Rectangle

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Text Box

SEE NOTE

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Line

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Text Box

NOTE: RAM AML/HML MANLIFTERS REQUIRE FOUR (4) SPRINGS ONLY (See Next Page)

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Rectangle

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33

Spring Kits

QTY. 901537 9100307 930913

Spring Retaining Ring

Flat Head Socket Cap Screw

AM7HBA0B1 14(Use all the spring pockets) 1 2

AM7HBB0B1 12(Use all but 1 & 8) 1 2

AM7HBC0B1 10(Use all but 3, 6, 10, & 13) 1 2

AM7HBD0B1 9(Use all but 3, 6, 8,10, & 13) 1 2

AM7HBE0B1 8(Use all but 1, 3, 6, 8, 10, & 13) 1 2

* Assemble springs to designate spring pockets

P/N

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Oval

cclements

Oval

cclements

Oval

cclements

Oval

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Text Box

INSTALL SPRINGS ONLY IN LOCATIONS 3, 6, 10, 13

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Rectangle

12

3. Back Flat Head Cap Screws (22) incrementally out of Piston (8A) until spring force is relieved

from the Pressure Plate (8B). Then, remove Flat Head Cap Screws (22) and Pressure Plate (8B) from brake cavity in Spindle (1A).

4. Remove Compression Springs (8L) from Piston (8A).

CAUTION: Eye protection must be worn while performing the next step in this procedure. 5. Using an air hose, slowly and carefully pressurize the brake port in the Spindle (1A) until the

Piston (8A) comes out of piston bore of Spindle (1A), Then pull the Piston (8A) the rest of the way out of the Spindle (1A) by hand.

6. Remove Backup Rings (8E) & (8H) and O-rings (8D) & (8F) from grooves in Piston (8A). 7. Remove Rotors (8J) and Stators (8K) from brake cavity in Spindle (1A). 8. Remove Coupling Subassembly (7) from brake cavity in Spindle (1A). 9. Remove Retaining Ring (1K) out of the internal groove using appropriate tool. 10. Remove the Spacer (1M) & Spring (1L) out of the bore of Coupling (7). 11. Remove Plastic Plug (12) & Pipe Plug (21) from Spindle (1A) if applicable. This completes the Spindle-Brake Disassembly.

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Rectangle

16

7HB(A, B, C, D, E, X) SPINDLE - BRAKE SUBASSEMBLY

1. Place Spindle (1A) such that the flange side is up. 2. Place Stator (8K) into the Spindle (1A) scallop cuts. 3. Place Rotor (8J) on top of Stator (8K). 4. Repeat steps 2 & 3 until there are a total of 9 Stators (8K) and 8 Rotors (8J) installed. 5. Place Piston (8A) such that the smaller O.D. end is facing upward. Grease the two O-Rings and the two Backup Rings. 6. Install large Backup Ring (8E) in the large-diameter groove at the bottom of the Piston (8A). 7. Install large O-Ring (8D) in the large-diameter groove at the bottom of the Piston (8A), on top of the large Backup Ring (8E). 8. Install small O-Ring (8F) in the small-diameter groove near the top of the Piston (8A). Make sure the O-Ring is seated on the bottom of the groove. 12. Install small Backup Ring (8H) in the small-diameter groove near the top of the Piston (8A), on top of the small O-Ring (8F). 10. Insert Piston (8A) into Spindle (1A) until it contacts the Stator (8K). 11. Insert the appropriate number of Springs (8L), based on the assembly print, into Piston (8A) counterbore. 12. Place Spring (1L) into Coupling (7) counterbore. Place the Pressure plate (1M) on top of Spring (1L). 13. Use appropriate tool to install Retaining Ring (1K) into the retaining ring groove in the

Coupling (7) counterbore. 14. Insert Coupling sub-Assembly (7) through Rotors (8J) 15. Place Pressure Plate (8B) on top of Springs (8L) 16. Use two ¼ -20 x .625 flat head Cap Screws (22) by bolting the Pressure Plate (8B) and

Piston (8A) together or some other appropriate tools to install Retaining Ring on top of Pressure Plate (8B) until Retaining Ring (8C) is seated.

Note: Remove 2 Screws from units when done, otherwise brake will not function.

17. Install Pipe Plug (21) if applicable

The Spindle-Brake Sub-Assembly is now complete.

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Rectangle

22

ASSEMBLY DRAWING - 7HB(A, B, C, D, E)

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Rectangle

23

PARTS LIST - 7HB(A, B, C, D, E)

ITEM QUANTITY DESCRIPTION 1A 1 SPINDLE 1B 1 LIP SEAL 1C 2 TAPERED BEARING ASSEMBLY 1D 1 HOUSING 1E 1 RING GEAR 1F 1 Bearing Nut 1G 2 SOCKET HEAD SET SCREW (.250-28,.500) 1H 9 STUD 1K 1 RETAINING RING – INT 1.250 1L 1 SPRING (1.225,1.500) 1M 1Q

1 1

THRUST WASHER SEAL BOOT (if applicable)

2 1 THRUST SPACER 3A 1 CARRIER 3B 6 THRUST WASHER 3C 42 NEEDLE BEARING 3E 3 PLANET SHAFT 3F 3 PLANET GEAR 4B 12 THRUST WASHER 4C 84 NEEDLE BEARING 4D 3 THRUST SPACER 4E 3 PLANET SHAFT 4F 3 PLANET GEAR 4G 6 ROLL PIN 4H 1 THRUST WASHER 5 1 RETAINING RING – EXT .875

6A 1 COVER 6B 1 DISENGAGE CAP 6C 2 BOLT, HEX (.250-20 UNC, .500 GR5) 6D 1 DOWEL PIN 6E 1 O-RING 6F 2 PIPE PLUG 6G 1 RETAINING RING – INT 7.086 7 1 COUPLING

8A 1 BRAKE PISTON 8B 1 PRESSURE PLATE 8C 1 RETAINING RING – INT 4.000 8D 1 O-RING 8E 1 BACK-UP RING 8F 1 O-RING 8H 1 BACK-UP RING 8J 8 BRAKE ROTOR 8K 9 BRAKE STATOR 8L 10 SPRING, H.D. (.492,1.260) 9 1 INPUT SHAFT

10 1 SUN GEAR 1st stage ( Applicable on ratio’s 36:1 & lower)

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Rectangle

24

11 1 SUN GEAR 2nd stage 12 1 O-RING PLUG or PLASTIC PLUG 15 1 ID PLATE 16 4 DRIVE SCREW 17 1 O-RING 18 1 O-RING 19 3 BOLT, FLAT HEAD - HEX SKT (.375-16) 20 1 RETAINING RING - EXT 1.562 21 1 O-RING PLUG

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Rectangle

32

Brake Service Kits

Lining Kit

AM7HB00A1

ITEM DESCRIPTION PART No. QTY.

8J Reaction Disc, Brake Rotor 902426 8

8K Friction Disc, Brake Stator 902427 9

Seal Kit AM7HB00C1 1

Seal Kit

AM7HB00C1

ITEM DESCRIPTION PART No. QTY.

8C Retaining Ring 9100307 1

8D O-Ring 9400102 1

8E O-Ring, Back-up 9400248 1

8F O-Ring 9400250 1

8H O-Ring, Back-up 9400249 1

Flat Head Socket Cap Screw 930913 2

cclements

Rectangle

cclements

Text Box

RAM P/N AG00304 - BRAKE and SEAL KIT

cclements

Text Box

RAM P/N AG00305 - SEAL KIT

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Rectangle

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Rectangle

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Rectangle

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Rectangle

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Rectangle

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Rectangle

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Rectangle

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Rectangle

Installation / Maintenance / Servicing

INSTALLATION1. Mounting Positions

The motor is normally mounted in a horizontal position with the filler / breather plug towards the top (Fig. 1) It may alsobe mounted with the shaft vertically downwards (Fig. 2). As supplied the motors have been run up and tested using protective oil and then drained for transit.It is vital that each motor is re-filled to the correct oil level

as shown below.

The motors have a dipstick for verticalmounting (Fig. 2) and the lower mark on this dipstick provides the oil level. Oil levels are achieved on motors inthe horizontal postion by filling to the plugs marked 60.

2. Recommended Lubricants for normal

ambient temperature (0 - 32 deg. C.)

ShellB.P.EssoRegentCastrolMobil

CrankcaseTELLUS 100ENERGOL HL175NUTO H.64REGAL PE.ROHYSPIN 175D.T.E. EXTRA HEAVY

AirlineTELLUS 37ENERGOL HLP65FANOX 38RANDO 'A'HYSPIN 70ALMO OIL NO. 1

For extremes of ambient temperatures consult the manufactures

3. Air Inlet

The motor is normally supplied with inlet / exhaust adaptor plate (72). All motors are reversible.

4. Air Supply. Maximum Working

Pressure 8 bar - 120 psi

The air supply must be clean and free from moisture. An airline filter and mist lubricator should be incorporated in theair supply line, located immediately before the motor. If the rated performance of the motor is to be obtained all valves and pipework must be of adequate size. Valves should be sited as close as possible to the motor. For short pipe runs e.g. up to 2 metres the supply line should be the same size as the motor ports and larger for longer runs.

5. Fitting

Mount motor in operating position. Check oil level. (as 1 above). Before connecting to the air supply blow out the air lines to remove any loose scale, swarf or abrasive dust which may be present.Remove the red plastic dust-caps and the 'O' ring seal (45).

For unidirectional operation check the required direction of rotation and connect the air supply line to the appropriate port on the inlet / exhaust adaptor plate (72) leaving the otherport open or pipe downwards if exposed to the atmosphere.

The motor should not be allowed to race. Always operate within the catalogue speed curves.

Horizontal Oil Level

Breather / Filler Plug

A B

Shaft rotation as shown with inlet 'A'Reverse rotation is obtained with inlet at 'B'

Dipstick(Only fitted on

OilLevel

Fit elbow andbreather plug(for ease offilling in thevertical position)

Fig. 1 Fig. 2

Motor Mounting Positions

Note! When first running the motor some light oil should beinjected into the inlet connection to ensure adequatelubrication until the airline lubrication is established.

Maintenance

6. Air Supply

The air filter should be drained regularly and examined forclogging of the element.The air line lubricator should be replenished as requiredand set to give 4-5 drops per per minute.

Double the above drip rate if intermittent operation.

7. Motor

The oil level in the motor casing must be maintained. The frequency of replenishment will depend on the application and usage.The motor case should be drained and refilled after 25 hours of initial running and every 200 hours thereafter or sooner if found neccessary e.g. (contamination of oil by water from the air line.)

Fault Finding

1. The motors are designed to perform at theirrated capacities for the long periods of time. Faults candevelop for the following reasons:(A) Lack of lubrication. This will leave to rapid wear, internal seizure, loss of power or excessive air leakage.(B) Faults in the air supply system:1. failure to remove the plastic protective dust caps2. insufficient air pressure at the motor caused by (a) supplypipe line or valve too small (b) if the exhaust is piped away ecessive back pressure due to small bore pipes (c) compressor of insufficient capacity (d) clogged airline filter (e) the air pressure should remain at the required pressure when the motor is operating at full potential.

If the air pressure reduces considerably from the stationary to the rotating conditions then the supply line or the compressed air avaiable is inadequate for the service operation of the motor.

The motor should always be supplied with clean moisture free and lubricated air. The better the quality of the air the less attention will be required to the motor unit.

RAM P/N I400210 AIR MOTOR RAM P/N I400015 AIR MOTOR

QtyNo. Description

Air Motor Assembly 1

1 Rotary Valve Bearing (Outer) 12 Rotary Valve 13 Rotary Valve Housing 14 Rotary Valve Bearing (Inner) 15 Rotary Valve Bearing Circlip 16 Rotary Valve Housing Gasket 17 Cylinder Gasket 48 Cylinder 49 Piston Assembly 4

10 Compression Ring 411 Oil Control Ring 412 King Rod 113 Crankshaft Spacer 114 Crankshaft Circlip 115 Crankshaft Spacer 116 Crankshaft Spacer Shim 518 Crankshaft Bearing Circlip 219 Crankshaft Oil Seal 1

Figure 2. RM210, RM310 & RM410 Motors

RAM P/N I400210 AIR MOTOR

20A

AIR MOTOR RAM P/N I400015

QtyNo. Description

20A Standard Crankshaft Assembly 124A Standard Flange Plate 125 Flange Plate Seal 126 Plug 127 Engine Case 129 Queen Rod Pivot 330 Queen Rod 331 Crank Spacer 132 Crank Spacerr 133 Crank Spacer 134 Crank Spacer 135 Balance Weight 136 Woodruff Key 137 Cylinder Bolts 1638 Valve Housing Bolts 439 Washers for Valve Housing Bolts 440 Adapter Plate Bolts 441 Exhaust Cover Bolts 243 Breather Plug Seal 144 Dipstick 145 Seal (For Transit Only) 146 Breather Plug 147 Oil Seal Carrier 148 Needle Bearing 1

Needle Bearing 249 Grub Screw 150 Key 151 Rotary Valve Exhaust Cover 152 Countersunk Flange Bolts 454 Nylon Washer 155 Output Shaft Bearing (Outer) 15 6 Output Shaft Bearing (Inner)60 Oil Level Plug 172 Inlet Adapter Plate 173 Inlet Adapter Plate Gasket 175 Dipstick Seal 176 Seal Kit (Includes Ref. Nos. 6, 7, 10,

11, 19, 25, 43, 73 and 75) 1


RAM AG78762 Crankshaft Assy


RAM P/N AG00146

RAM P/N AG00152

AG00146 -- 150 psig/10 bar max.

AG00152 -- 300 psig/21 bar max.

AG00152 - 14.0 SCFM @ 50 psig;25 SCFM @ 100 psig; 600 l/min @ 6 bar

AG00146 - 7 SCFM @ 50 psig;12 SCFM @ 100 psig; 600 l/min @ 6 bar

AG00152 - 38 oz. nominalAG00146 - 36 oz. nominal

15/32 - 32 thread. Nuts and lockwashers furnished.

AG00152 ......... Normally-Closed Poppet Valve, 1/8" NPT

AG00146 ......... Normally-Open Spool Valve, 1/8" NPT

RAM P/N AG00144 POPPET VALVE

Basic Size 1” Port Size 1” Operating Pressure psig (bar)

0-300 (0-20.7)

Pilot Pressure psig (bar) 30-300 (2.1 – 20.7) Weight lbs. (kg) 3.69 (1.68)

RAM P/N AG00180 Flow Control Valve

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0.070 dia.

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#5-40 thd.

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15

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15%

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15%

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15%

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15%

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15%

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15%

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15%

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Input Pressure: 2000 psig max. Air Flow: 3 SCFM @ 50 psig 6 SCFM @ 100 psig

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Flow - SCFM @ 100 psig

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Number of Needle turns

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7/16" Hex

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1/8" NPT inlet

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#10-32" outlet

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#5-40 thd. Flow Adjustment

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0.125 max

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0.343 max

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1.187

RAM P/N AG00221 RELIEF VALVE

Body Material: Stainless Steel Connection 1 Size: ½” Connection 1 Type: Male NPT Taper Thread Connection 2 Size: ½” Connection 2 Type: Male NPT Taper Thread Cracking Pressure: 50 – 150 PSI (Adjustable) eClass: 37010801 Feature: 50 - 150 PSI (Adjustable) UNSPSC Code: 40141601

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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†

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1 2 3

OUT

IN IN

RAM P/N AG03315R

RAM P/N AG04717 E-Stop Valve

System Pressure 0-150 psi (0-10 bar)Allowable Backpressure at exhaust port 0MaterialsValve body and caps: 316 Stainless steel (NACE Standard MR-01-75)Valve Seals: FKM (Fluorocarbon) O rings Screws: Stainless steel Lid Knob: Synthetic resin Porting Size and Flow Inlet, Outlet & exhaust ports: ¼” NPT Internal orifice: 3/8” (9.5 mm) Weight0.1.0 lbs (.45 kg)

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RAM P/N AG70031

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Rectangle

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Text Box

AML336AK-1G-0 RAM WINCH & HOIST 03/2014

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