14603 CHRISMAN HOUSTON, TEXAS 77039 (281) 999-8665 FAX: (281) 999-8666 or (888) 726-5438

Instructions, Parts and Maintenance Manual

INVADER

MODEL K5UR100ML

UTILITY AND MANLIFTER AIR WINCH

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 Continued 4.0 Operating Instructions 4.1 Operator Start Up 4.2 Shutdown 5.0 Preventive Maintenance 5.1 Introduction 5.2 Maintenance Plan 5.2.1 Lubrication Schedule 5.2.2 Cleaning 5.2.3 Cable and Hoses 5.2.4 In Field Load Brake Adjustment Procedure 6.0 Component Removal/Replacement Appendices Personnel Rating Performance Characteristics Utility Rating Performance Characteristics RAM Winch & Hoist Parts Information Avenger 100 General Arrangement Drawing Avenger 100 Drum Guard Drawing Avenger 100 Exploded View Figures 1 through 5 Avenger 100 Winch Assembly Bill of Material Avenger 100 Manual Brake Bill of Material Avenger 100 Auto Brake Bill of Material Avenger 100 Manual & Auto Brake Bill of Material Avenger 100 Recommended Spares K5U Air Motor Parts Listing K5U Air Motor Assembly Illustration Power Wheel Service Manual Model 9

1.0 General Information 1.1 User Responsibility and Safety Precautions

MODEL IDENTIFICATION The exact model number of your winch is located on the RAM winch nameplate permanently mounted on the winch. The RAM model number identification chart located on the inside of the front cover of this manual explains the model number codes for the various features provided on your winch.

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 checked periodically. 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 operating instructions and maintenance procedures for

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

and serial numbers 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 winch is an air, planetary driven cable-handling unit with manual release and auto release

band brakes, designed for use in the marine or industrial environment.

cclements

See Performance Chart

BILL OF MATERIALS “DAUNTLESS” (K5UR50), “DAUNTLESS D” (K5UR50D),

“AVENGER” (K5UR90), “AVENGER” (K5UR100), “INVADER” (K5UR120)

WINCH ASSEMBLY CONTINUED

ITEM QTY PART NUMBER DESCRIPTION WT (LBS) K5UR-032-24 20” or 24” Between Flanges 33 K5UR-032-30 26” or 30” Between Flanges 39 K5UR-032-36 32” or 36” Between Flanges 44

6 6 HUR-010 Tie Bar Flange Bolt 3 7 6 HUR-018 Tie Bar O-Ring, Small 0 8 6 HUR-222 Tie Bar O-Ring, Large 0 9 1 GEARBOX ASSEMBLY K5UR50-A353 For Dauntless 105 K5UR50D-A353 For Dauntless D 105 K5UR90-A353 For Avenger 90 169 K5UR100-A353 For Avenger 100 169 K5UR120-A353 For Invader 169

10 10 DRUM/GEARBOX HEX BOLT K5UR50-354 For Dauntless & Dauntless D 2 K5UR90-354 For Avenger & Invader 2

11 10 LOCKWASHER K5UR50-TAB For Dauntless & Dauntless D 0 K5UR90-TAB For Avenger & Invader 0

12 8 FRAME/GEARBOX HEX BOLT K5UR50-355 For Dauntless & Dauntless D 2 K5UR90-355 For Avenger & Invader 2

13 8 AG78056 WASHER 0 14 1 INTERFACE SHAFT

K5UR-506 For Dauntless/Dauntless D & Avenger 3.5 K5UR120-506 For Invader 5

15 2 K5UR-016 Shaft Oil Seal 1 16 1 KD5-A501 Air Motor W/Controls 360 17 10 KX-36 Frame/Motor Hex Bolt 2 18 10 A-67 Lockwasher 0 19 1 KU-895 Bearing, Crank Motor End 1 20 1 KK5UM-545 Valve Chest 21 1 KU-546A Valve Chest Cover 22 4 KU-548 Hex Head Capscrew 1 23 4 D10-322 Lockwasher 1 24 1 K5UR-466 Bearing 4 25 1 K5UR-508 Bearing End Cover 3.5 26 4 D02-354 Hex Head Capscrew 1 27 4 D02-321 Lockwasher 0 28 2 HUR-165 Oil Hex Plug 0 29 1 HUR-381 Rope Locking Wedge 1 30 1 DRUM/GEARBOX GASKET

HUR-594 For Dauntless & Dauntless D 0 HUR-594 For Avenger & Invader 0

31 1 FRAME/GEARBOX GASKET HUR-593 For Dauntless & Dauntless D 0 K5UR-593 For Avenger & Invader 0

32 1 HUR-592 Frame/Motor Gasket 0 33 1 HUR-595 Bearing End Cover Gasket 0

See Fig. 1

RECOMMENDED SPARES “DAUNTLESS” (K5UR50), “DAUNTLESS D” (K5UR50D),

“AVENGER” (K5UR90), “AVENGER” (K5UR100), “INVADER” (K5UR120)

QTY PART NO DESCRIPTION

1 HU-942 Poppet Throttle Valve Spring 1 KU-527 Large Valve Drive Pin 2 HU-527 Small Valve Drive Pin 1 HU-556 Throttle Lever 1 HU-567 Throttle Lever Latch Spring 1 KU-519 Crank Pin Sleeve 1 KU-518 Crank Valve End Bearing 1 KU-895 Crank Pin End Bearing 1 KU-337-5 Piston Ring Set 1 KU-338-5 Oil Regulating Ring Set 5 KU-507 Cylinder Gasket 1 K5M-592 Motor Case Gasket 1 K5UR-466 Drum Bearing 1 K5UR-508 End Cover Bearing 2 HUR-162 Clevis Pin 1 HUR-720 Air Cylinder 1 HUR-726 Compressor Spring 1 HUR-715 Brake Handle 1 KU-940 Poppet Throttle Valve 1 KU-943 Poppet Throttle Valve Cap 1 HU-870 Throttle Lever Pin 1 K6U-412 Throttle Lever Spring

Recommended Spares for two (2) Year Foreign Operation FOB: Houston, Texas Terms of Payment: Net 30 Days

RAM P/N AH04414R

Double Reduction Wheel Drive SERVICE MANUAL

AUBURN, INDIANA 46706-3499U.S.A.

PHONE: (219) 925-3200FAX: (219) 925-4725

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DISASSEMBLY OF POWER WHEEL Refer to Parts Illustration STEP 1 Slide the coupling (1) from splines on input shaft (2). STEP 2 Position the assembly upright on face of spindle (3). STEP 3 Remove the disengage cover (30) if necessary. STEP 4 Remove twenty-four bolts (26) and flat washers (27) and the large cover (25) from the unit. The thrust washer (22) and the disengage plunger (23) usually remain attached to the large cover (25) when it is removed. Remove thrust washer (22), disengage plunger (23) and “O” ring (24) from the large cover (25). STEP 5 Remove primary sun gear (21) from end of input shaft (2). STEP 6 Remove the primary carrier assembly (20). STEP 7 Remove the secondary carrier assembly (19). It may be necessary to remove the ring gear (18) first, if difficulty is encountered removing the carrier. STEP 8 Remove the input shaft (2) from spindle (3). Remove the retaining rings (15), washer (16), and disengage spring (17) from input shaft (2) only if replacement is required. STEP 9 If not previously removed (see step 7) remove ring gear (18) from hub (9). It may be necessary to strike ring gear (18) with a rubber mallet to loosen from hub (9). STEP 10 One tab of lock washer (13) will be engaged in the slot of bearing nut (14); bend back to release. Remove the bearing nut (14), lock washer (13) and thrust washer (12). Note: A special locknut wrench, 593RR, required for the removal of the bearing locknut. Contact RAM Winch & Hoist for procurement of wrench and other service tools. STEP 11 Bolt spindle drive tool, 598FF, to hub (9). Drive spindle (3) from hub (9) by turning bolt in center of spindle drive tool. Care should be taken to avoid damaging splines and threads on spindle. Note: Bearing cone (11) has been designed with a press fit with respect to spindle (3). Considerable force will be required to remove cone from spindle. STEP 12 Remove the boot seal (4) and oil seal (5) and bearing cones (6 & 11) from hub (9). Inspect bearing cups (7 & 10) in position and remove only if replacement is required.

AUBURN, INDIANA 46706-3499U.S.A.

PHONE: (219) 925-3200FAX: (219) 925-4725

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ASSEMBLY OF POWER WHEEL STEP 1 Press new bearing cups (7 & 10) in each side of the hub (9). It is recommended that bearing cups (7 & 10) and cones (6 & 12) be replaced in sets. STEP 2 Assemble bearing cone (6) into cup (7) at seal end of hub (9) and press a new seal (5) into hub (9). Install boot seal (4) on hub (9) if unit is so equipped. STEP 3 Position spindle (3) upright on bench. Lubricate lips of seal (4) and (5) and lower hub (9) onto spindle (3). Hub (9) should be centered as it is lowered over spindle (3) to prevent seal damage. STEP 4 Assemble bearing cone (11) over spindle (3). Press bearing cone (11) over spindle bearing journal using press and cylindrical bearing cone driver 598F. Pressure bearing cone (11) down until rollers just touch cup (10). Take care to avoid pressuring cone (11) too far. Note: If a press is not available, place tool 598F over splined end of spindle (3) on the edge of bearing cone (11) and drive into place with hammer or mallet. If this method is used, care must be taken to avoid damage to bearing cone and spindle. STEP 5 Install thrust washer (12) and bearing nut (14). DO NOT install lock washer (13) at this time. STEP 6 Place spindle drive tool, 598F, over spindle (3) and bolt or pin to hub (9). STEP 7 Check initial rolling torque by installing a lb.-in. torque wrench (arm or dial type) on center nut of spindle drive tool and turning hub (9) slowly and steadily with the torque wrench. Note mean torque. An initial bearing torque of greater than 52-lb. –in. with boot seal installed or 48 lb. –in. without boot seal means that the cone (11) was pressed on too tightly in step 4. In this case, back off bearing cone (11) by pressing spindle (3) out of cone (11) until initial preload is relieved. See step 11 of disassembly procedure. STEP 8 Torque bearing nut (14) with bearing nut wrench 593RR until a bearing rolling torque of 44 – 52 lb. – in., with a boot seal installed, or 40 – 48 lb. –in., without a boot seal, is reached. This may require several trials of pressing the cone (11) by torquing the nut (14) and then checking the rolling torque. Rotate hub (9) by hand as nut is being tightened in order to seat bearings. Note: Up to 250 lb. –ft. of torque may have to be applied to bearing nut (14) in order to press cone (11) into position. STEP 9 Remove bearing nut (14) and install lock washer (13). Replace bearing nut (14). STEP 10 Re-torque bearing nut (14) to 65-75lb. – ft. (88 – 100 Nm).

AUBURN, INDIANA 46706-3499U.S.A.

PHONE: (219) 925-3200FAX: (219) 925-4725

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STEP 11 Secure bearing nut (14) by bending a lock washer (13) tab into one of four bearing nut slots. If no tab aligns with a slot, the nut may be tightened until one of the slots aligns with a lock washer tab. STEP 12 Assemble a washer (16), spring (17), a second washer (16), and a retaining ring (15) in the middle grooves of input shaft (2). Install a second retaining ring (15) in groove near small end of input shaft (2). STEP 13 Assemble the splined end of the input shaft (2) down into spindle (3). STEP 14 Assemble the secondary carrier assembly (19) to spindle (3) at splines. STEP 15 Clean mating surfaces and apply a bead of silicone sealant to face of hub (9) that mates with ring gear (18). See instructions on sealant package. Assemble ring gear (18) to hub (9) being careful to align bolt holes. STEP 16 Assemble the primary carrier assembly (20) into the ring gear (18). It will be necessary to rotate carrier to align secondary sun gear {part of primary carrier assembly (20)} with planet gear teeth in secondary carrier assembly (19). Assemble primary sun gear (21) over input shaft (2). Rotate primary sun gear (21) to align input shaft (2) to gear splines and gear teeth in primary carrier assembly (20). STEP 17 Lubricate “O” ring (24) and assemble in groove inside cover hole, push disengage plunger (23) into cover (25) with pointed end facing inside of unit. STEP 18 Assemble the thrust washer (22) with tangs engaged with cover (25). NOTE: A small amount of grease applied to the back side of thrust washer (22) will hold washer in place. Apply a bead of silicone sealant to end of face of ring gear (18). Assemble cover (25) aligning holes of cover and ring gear. Assemble the twentyfour 3/8-16 x 6-1/2 inch grade 8 bolts (26) and flat washers (27). Torque bolts to 45 - 50 lb.-ft. (61 - 67 Nm). STEP 19 Assemble the disengage cover (30) with dimpled center protruding out if wheel is to be used to drive the vehicle. Assemble and torque the two 5/16-18 x 1/2 inch bolts (31). Torque bolts to 10 - 20 lb.-ft. (13 - 27 Nm). STEP 20 Invert the Power Wheel assembly and assemble the coupling (1) with counter bore out to the input shaft (2) STEP 21 After motor is assembled to drive or drive is sealed at spindle, fill with lubricant to proper level and replace all plugs. Note: When installing a hydraulic motor to the Power Wheel drive it is necessary to place an “O” ring or gasket between the motor and the planetary drive. “O” ring sizes: SAE A 2-042, SAE B 2-155, SAE C 2-159.

CARRIER ASSEMBLIES

It is recommended that the primary and secondary carrier assemblies (18 & 19) be serviced entirely to protect the integrity of the Power Wheel drive. LUBRICATION RECOMMENDATIONS IMPORTANT: POWER WHEEL PLANETARY DRIVES ARE SHIPPED WITHOUT LUBRICANT AND MUST BE FILLED TO THE PROPER LEVEL PRIOR TO START UP. Observe lubrication recommendations given by the original equipment manufacturer. When specific recommendations are not available, use mild extreme pressure lubricant API-GL-5, No. 80 or 90 when filling the Power Wheel under normal temperature ranges between 0 - 120°F (-18 to 49°C). Power Wheel is to be half full of oil when unit is mounted level and horizontal. Use drain and fill plugs located in cover and ring gear. Oil is to be changed after first 50 hours of operation with subsequent changes every 1000 hours or yearly, which ever comes first. If unit is to be operated vertically, if ambient conditions are outside the specified range, or if the oil temperature exceeds 200°F (93°C) contact RAM Winch & Hoist for oil and level recommendations. STORAGE A protective film is applied to the Power Wheel at the factory to prevent rust during shipment. Additional protection may be required if the Power Wheel is to be stored for an extended period of time. SEALING COMPOUND Silastic RTV732 sealer and General Electric Silimate RTV No. 1473 or RTV No. 1503 are currently recommended for sealing gasket surfaces. Sealant should be applied in continuous bead, which should be centered on the surface to be sealed but should move to the inside of the hole at each bolt hole location. For service requirements order RAM Winch & Hoist part number 604101.

SPECIFICATIONS Maximum intermittent output torque ..........................................................130,000 lb. In. (14,690 Nm) Maximum input speed ................................................................................5,000 RPM Oil capacity……………………………………………………………………....57 oz (1,685 ml)

AUBURN, INDIANA 46706-3499U.S.A.

PHONE: (219) 925-3200FAX: (219) 925-4725

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PARTS LISTING

Refer to Parts Illustration Drawing for Item Numbers

Item No.

Description

No. Used in Ass’y.

Item No.

Description

No.Used in Ass’y.

1 Coupling 1 18 Ring Gear 1

2 Input Shaft 1 19 Secondary Carrier Assembly 1

3 Spindle 1 20 Primary Carrier Assembly 1

4 Boot Seal 604403 1 21 Primary Sun Gear 1

5 Oil Seal 604409 1 22 Thrust Washer 1

6 Bearing Cone 14-00-133-007 1 23 Disengage Plunger 1

7 Bearing Cup 14-00-133-006 1 24 “O” Ring 614101 1

8 Wheel Bolt 8-10 25 Large Cover 1

9 Hub 1 26 Hex Head Bolt (Grade 8) 24

10 Bearing Cup 613314 1 27 Flat Washer 24

11 Bearing Cone 613315 1 28 Magnetic Plug 14-00-052-002 1

12 Thrust Washer 619320 1 29 Pipe Plug 1

13 Lock Washer 605003 1 30 Disengage Cover 14-02-039-005 1

14 Bearing Nut 2 31 Hex Head Bolt 618305 1

15 Retaining Ring 2 32 Quick Disconnect Gasket 1

16 Washer 1 33 Quick Disconnect Assembly 2

17 Disengage Spring 615604 1 34 Hex Head Bolt 2

Contact RAM Winch & Hoist at (281) 999-8665 with model number, item number and description to obtain the appropriate parts. Refer to parts list for the specific item numbers and quantities.

Model 9 Power Wheel Service Kits

Part No. Description Included Items 593RR Bearing Locknut Tool Not Shown 598F Bearing Cone Driver Not Shown 598FF Spindle/Shaft Drive Tool Not Shown

RAM P/N LB80045R LUBRICATOR

Specifications

Proof Pressure psig (Mpa) 220 (1.5)

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

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

Recommended Lubricant Turbine Oil #1 (ISO VG32)

Pipe Size 1 ½” NPT

Oil Capacity (cm3) 500

Flow Rate /n/min 12500

RAM P/N LB80040R FILTER

Specifications Pipe Size 1 1/4

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

Weight lbs. (kgf) 6.94 (3.15)

Proof Pressure psig (Mpa) 220 (1.5)

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

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

Filtration 40 µm

Flow Characteristics

RAM P/N LB80050 REGULATOR

SPECIFICATIONS

Port Size 1 ½

Proof Pressure psig (Mpa) 220 (1.5)

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

Temperature 23 ~ 140° (-5 ~ 60C

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

Body AC2A-F

Bonnet ADC

Chamber AC2A-F

Valve Guide AC2A-F

Weight lbs (kgf) 5.51 (2.5)

FLOW CHARACTERISTICS Conditions: Supply Pressure 100 psig

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

No. Name Material Part No.

5 Exhaust Valve Assembly --- 132586A

6 Main Valve Diaphragm Assembly --- 13275A

7 Valve Assembly --- 132752A

8 Regulating Spring SWPB 135053

9 Valve Spring SUS304 132713

11 Pilot Diaphragm --- 135019-1A

Dimensions

A B C D E F

6.30 (160)

9.53 (242)

3.50 (89)

5.51 (140)

4.45 (113)

0.39 (10)

POWER WHEEL Service Manual RAM Winch & Hoist