Mustang General Assembly Drawing. Mustang Exploded View Figures 1 through
5. Mustang Winch Assembly Bill of Material. Mustang Manual Brake Bill of ...
Instructions, Parts and Maintenance Manual
MUSTANG MODEL HUR40 UTILITY 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.
14603 CHRISMAN
HOUSTON, TEXAS 77039
(281) 999-8665
FAX: (281) 999-8666
or
(888) 726-5438
TABLE OF CONTENTS
Warning Tags Mustang Safety Instructions Safety Guidelines Winch Operating Practices 1.0
General Information
1.1
User Responsibility and Safety Precautions
1.2 Introductions 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 Specifications and Descriptive Data 2.0
Functional Description
2.1 Major Assemblies 2.1.1 Drive Assemblies 3.0
Installation Instructions
3.1
Site Selection
3.2
Handling
3.3 Installation Procedures 3.3.1 Welding/Bolt Down 3.3.2 Requirements Prior to Start Up 3.4 Installation Checkout 3.4.1 Phase-1 Installation Inspection 3.4.2 Phase-2 Start Up And Preliminary Tests 3.5 Cable Installation 3.5.1 Cable Termination on Drum 3.5.2 Spooling Cable onto Drum
Table of Contents Continued 4.0
Operating Instructions
4.1 4.2
Operator Start Up 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 Utility Rating Performance Characteristics RAM Winch & Hoist Parts Information Mustang General Assembly Drawing Mustang Exploded View Figures 1 through 5 Mustang Winch Assembly Bill of Material Mustang Manual Brake Bill of Material Mustang Auto Brake Bill of Material Mustang Manual & Auto Brake Bill of Material Mustang Recommended Spares HUR Air Motor Parts Listing HUR Air Motor Assembly Illustration Power Wheel Service Manual 6 Manual Double Reduction Wheel DriveModel Service Component Data Sheets
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 winch with adequate factors of safety for the rated load, plus the weight of the winch and attached equipment. A registered structural engineer should review handling procedures.
! WARNING ! Failure to follow these warnings may result in death, severe injury or property damage: • Do not operate this winch 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 winch drum at all times to ensure this. • Do not operate a damaged or malfunctioning winch. • Do not remove or obscure warning labels. • Any labels that become obscured or removed should be replaced as soon as possible.
MUSTANG Do Not Use this Winch for Personnel Handling. The items described in the following instructions are essential to insure that the winch 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
!
DANGER
!
WARNING
MEANING OF MARKING Indicates that errors may lead to very serious injury or death. 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 winch is to be used for utility purposes only. USAGE
!
DANGER
Never use this winch for lifting or lowering personnel onto a separate floating platform or vessel. This could result in serious injury or death. Prohibited
Never install and/or operate this winch without meeting all the applicable requirements as specified by the proper governing bodies (i.e. NORSOK, NPD, ABS, etc.). Failure to do so could result in severe injury or death. Never operate this winch 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 winch 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 to be in conformance for operation. Failure to do so could result in serious injury or death. TRANSPORTATION
!
WARNING
Never lift this winch 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. Prohibited
Never strap or tie down the winch 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
Never attach the winch base to a foundation unless properly reviewed by a competent Engineer. Failure to do so could result in injury, death or equipment damage. Prohibited
! Mandatory
Never use bolts to mount the winch to its base other than those specified in the manual. Failure to do so could result in injury, death or property damage. There must be an adequate foundation, which will withstand a minimum of five (5) times the maximum pull capability of the winch, for the winch base to be welded or bolted to. If the foundation is not adequate, it could be damaged or pulled out by the winch. Use the proper manufacturer specified bolts to secure the winch to the base. If the proper bolts are not used, and fail, the winch 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 winch to break loose. Under-torqued bolts may allow the winch to move slightly on the base. Provide and connect a clean source of air to the winch, which is regulated, not to exceed 100 PSI. If the air is not clean, it may cause the winch 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.
OPERATION AND OPERATING PRACTICES
!
Prohibited
DANGER
Never operate this equipment without prior training of winch use and all safety precautions. This includes all items pertaining to the complete lifting system, of which the winch is a component. Failure to do so could cause severe injury, death or equipment damage.
Never operate the winch unless all safety mechanisms are in place and working properly, and all winch 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 winch during operation. Failure to do so may cause the winch operator to become distracted and could result in injury, death or equipment damage. This could also result in injury to the loiterer. The operator must inspect the winch 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.
Mandatory
!
WARNING
Never lift a load greater than the rated line pull of the winch. This will exceed the winch limitations and could result in malfunction. Prohibited
Never operate the winch with twisted, kinked or damaged wire rope. This could lead to rope failure and result in rope breakage. Never operate the winch without guards in place. Failure to keep the guards in place could result in foreign items getting caught in the rotating portion of the winch 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 winch or should something inadvertently cause the winch to operate, someone could be injured. This winch must not be placed into operating service until the complete lifting system has been declared to be in conformity 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 winch 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. Anyone operating this winch 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 winch and cause damage to the equipment or personnel injury.
Mandatory A clear view of the complete winch and cable must be maintained. Make sure that the immediate area around the winch is clear of any trip hazards or slippery spots to prevent the operator or anyone else from falling into the winch or wire rope. Keep any loose gear, clothing, long hair, hands or feet away from the wire rope, winch levelwind and winch drum. These items are in motion and either rotating or moving linearly and could catch onto or pull item catching onto them into the winch. They could also smash, pinch or cause even more severe injury. Do not allow personnel to pass under where rider is located when suspended. 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. Winch 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 winch properly. The air supply to the winch must be turned off to prevent inadvertent operation.
All winch 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
!
Prohibited
DANGER
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. 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 winch 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.
! ! Mandatory
WARNING
Winch 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 winch 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.
This winch 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 winch must be maintained as required by applicable regulatory body. Failure to do so may cause winch 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. WARNING! Keep hands, feet and any loose clothing away from rotating or moving parts. Never operate the equipment with any guards or safety equipment removed from winch. Failure to do so may result in injury or death. When maintaining the equipment be sure to tag Out of Service on power supply to prevent accidental operation or activation. Do not alter or modify the equipment in any way without first contacting RAM Winch & Hoist Engineering Department as to the alteration type or extent. Failure to do so could result in damage to the equipment or injury to personnel.
18.
17.
16.
15.
14.
13.
12.
8. 9. 10. 11.
3. 4. 5. 6. 7.
2.
1.
35.
34.
32. 33.
31.
28. 29. 30.
26. 27.
25.
24.
23.
22.
21.
20.
19.
Post at Operating Station
Read the manufacturer's instructions before operating the winch. Always inspect, test maintain and operate this winch in accordance with American National Standards Institute Safety Standards B30.7. Never Lift a load greater than the rated line pull of the winch. Use the recommended size wire rope for load to be handled. Never use the wire rope as a sling. Always stand clear of the load. Never use the winch for lifting or lowering people, and never stand on a suspended load. Unless winch is designed for personnel handling. Never carry loads over people. Never disengage the clutch with a load applied to the winch. Never engage the clutch with the winch motor running. Always rig the winch properly and carefully, making certain the wire rope is properly anchored to the drum. Before each shift, check the winch for wear or damage. Check the brakes, wire rope, hooks, guides, mounting bolts, etc. Lift a capacity load or a near capacity load a few inches off the floor and check the ability of the braking system to stop and hold the load without excessive drift, if the winch is being used for lifting. Never operate a winch with a twisted, kinked or damaged wire rope. Periodically inspect the winch thoroughly and replace worn or damaged parts. Keep accurate records of all inspections and repairs. Follow the lubrication instructions provided by the manufacturer. Do not attempt to repair the wire rope or hooks. Replace hooks when there is a 15% increase in the throat opening or when there is a 10% bend as shown by inspection records. Keep the rope clean and well lubricated. Replace wire rope that is frayed. Ease the slack out of the wire rope when starting. Do not jerk the winch.
Form 2008
If the drum is exposed to personnel walkways, place a guard over the drum. Do not use your hands to guide the rope onto the drum when winding in the wire rope. Be certain there are no objects in the way of the load or hook when operating the winch. Do not use higher air pressure than recommended by the manufacturer. Use compressed air carefully. Be sure the hose couplings are secure, and make certain a safety chain is provided to avoid hose whip if the coupling fails. Wear proper clothing to avoid entanglement in rotating machinery. Be certain the air supply is shut off before performing maintenance on the winch. Properly secure a winch before leaving it unattended. Do not leave a load suspended for any extended period of time. Never leave a suspended load unattended. Do not allow unqualified personnel to operate a winch. Do not operate a winch if you are not physically fit to do so. Do not divert your attention from the load while operating a winch. Be certain the load is properly seated in the saddle of the hook. Do not tip load the hook as this leads to spreading and eventual failure of the hook. Do not force a hook into place by hammering. Never operate a winch beyond the point where less than four wraps of wire rope remain on the drum. Do not use the wire rope as a ground for welding. Do not attach a welding electrode to a winch or sling. Never operate a winch that makes excessive mechanical noise. Report the problem immediately.
WINCH OPERATING PRACTICES
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 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.
1.3.2
Specification and Descriptive Data Working Line Pull
See Performance Chart.
Cable Capacity
See Performance Chart.
Line Speed
Is variable from creep to full speed. See Performance Chart.
Construction
All steel with steel hardware.
Bearings
Spherical roller-type bearings.
Drive System
A piston-type air motor, coupled to a planetary gear reducer. The gear reducer output is bolted in the drum.
Controls
Manual air control valve is standard.
Braking System
This winch may have a manual band brake, an automatic band brake or both. !! WARNING !! Do not leave loads suspended on winch without operator present. Do not manually release the brake if a load is held suspended by the winch without operator or trained personnel present.
Performance
Bare drum rating as indicated on winch nameplate is the maximum allowable load.
2.0
Functional Description
2.1
Major Assemblies The winch consists of the following major assemblies: a. Drive assembly b. Frame and drum assembly
2.1.1
Drive Assemblies The drive assemblies consist of: a. Air motor to gear reducer assembly b. Gear reducer to drum assembly
3.0
Installation Instructions
3.1
Site Selection The winch 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 maximum winch line pull. ⇒ 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.
3.2
Handling Lifting the unit on the topside of the frame side plate (via lifting eyes) or under the frame structure will accommodate standard lifts. ** CAUTION ** DO NOT LIFT WINCH BY CABLE DRUM - DAMAGE TO CABLE AND/OR BRAKE ASSEMBLY MAY RESULT
3.3
Installation Procedures
3.3.1
Welding / Bolting Down When the winch is at or near the desired location, remove the shipping protection and position it exactly. If the winch is to be welded down, a qualified welder should be used. All exposed metal surfaces should be painted immediately after welding to inhibit rust. You must have a qualified engineer to determine the amount of weld required to securely hold the winch. If the unit is bolted down, be sure to use the proper size and a minimum of Grade 5 bolts and torque to the proper setting. ** CAUTION ** Extreme care should be taken to ensure the center of the winch drum exactly perpendicular to the cable running to the first sheave. This can be done by average sightings along the flat surface of the winch sidewall, drum flanges or with the help of a square to find the true perpendicular centerline. If it is not properly aligned, cable-laying problems may create difficulties and possibly damage the cable, winch and/or personnel.
3.3.2
Requirements Prior to Start Up Check gearbox lubrication for proper oil level. If it is low, fill to level mark on side. Fill with standard 90-wt. gear oil. There are two Allen hex plugs in the drum flange. To check the oil level for the gearbox, the drum should be rotated so one of the plugs is horizontal or on the side and one plug is on top. Remove the plug on the side. The oil should be filled to this level. If it is not, then add oil through the top plug. To drain the oil, rotate one port to the bottom. If oil level is adequate, replace the plug. Check lubricator on air supply line for proper oil level. If low, then fill with 30-wt. oil. Fill air motor to proper level with oil. Be certain all hoses and fittings are tightened and not leaking. See Section 5.0 Preventative Maintenance for Lubrication Schedule.
3.4
Installation Checkout
3.4.1
Phase 1 - Installation Inspection ⇒ Check all bolts and fasteners to ensure that they are tightened properly. ⇒ Grease all bearings. ⇒ Test manual brake release / set with no load on the drum to ensure operating properly.
3.4.2
Phase 2 - Start Up and Preliminary Tests ⇒ Leaks - All fittings and hoses have been inspected for leaks at the factory prior to shipment. If leakage is noticed, tighten or replace as required to correct.
3.5
Cable Installation
3.5.1
Cable Termination on Drum A cable lead-in slot is cut into the drum to allow termination inside the drum. A cable wedge is placed inside the drum pocket to constrain the cable.
** CAUTION ** This wedge is not intended to take full line pull on the cable.
3.5.2
Spooling Cable onto Drum Bring the cable under/over the drum and through the slot in the drum wall. Position the cable so it wraps around the wedge to secure the cable in the tapered slot. Handling and wrapping cable on the drum must be attended by a gloved operator to make certain that the cables lie on the drum properly. The cable must not stack up above the drum flanges or it will fall off the side of the drum and possibly damage the cable. Whenever the equipment is being raised, the winch operator must watch for the end of the cable markings or the equipment itself. Before the equipment gets near the sheave, the operator should stop the winch. ** CAUTION ** Spooling of the cable must be done very carefully. To prevent injury, keep hands, clothing and anything that could catch on or get caught in the cable clear when the drum is rotating. This would pull the item or person into the cable spooling onto the drum. Since spooling of the cable requires at least two people, an operator and someone to guide and control the cable, they must stay alert and maintain visual contact with each other at all times. We strongly recommend qualified and experienced personnel do this. For units with Levelwind, refer to spooling device instructions.
4.0
Operating Instructions
4.1
Operator Start Up ⇒ Ensure that control valve handle is in mid position. ⇒ Check that air supply is on and functioning properly. ⇒ Loosen the manual brake. ⇒ Move the control valve handle in the direction of desired operation (payout/retrieve). When lifting loads, the band brake should be used to help secure the load after lifting. When lowering the load, the control valve should be operated in the payout direction slightly while loosening the band brake. The band brake will help control the descent rate by the amount of drag allowed.
4.2
Shutdown / Turn Off ⇒ Release winch control handle (The valve handle should return to center or neutral positions.) ⇒ Shut off air supply. ⇒ Tighten band brake. ⇒ Do not shut the unit down with a suspended load that relies on the winch as the only support.
5.0
Preventive Maintenance
5.1
Introduction This section gives necessary information for regular periodic and preventive maintenance, and for some repairs or replacements. For further information, service assistance or problems, call RAM Winch & Hoist Service Department.
5.2
Maintenance Plan
5.2.1
Lubrication Schedule Under normal operating conditions on a permanent installation, the following lubrication schedule is recommended: 1.
The gear reducer is filled with oil at the factory. After 500 hours of operation, drain and refill with EP-90 weight lubricant.
2.
Lubricate the bearings with Lubriplate 130AA or equivalent at 50 hour intervals.
3.
WARNING: Lubricate the motor before operating the winch. To avoid leakage during shipment the oil is drained from the motor. A sufficient quantity of oil for filling each unit is packed with the winch. Make certain the proper lubricant is used for each unit. Make certain the oil level plugs and drain plugs are securely threaded into place. Remove the vent cap and oil level plug. Pour the recommended oil into the motor case until it starts to come out the level plug hole. Replace the level plug and vent cap.
Motor Lubrication Check oil daily and maintain level with opening in the side of the motor case. If the winch is being used more than four (4) hours per day, it may be necessary to check the level more often. When the winch is subject to temperatures above freezing: After the winch has been idle for several hours or overnight, loosen the drain plug located at the bottom of the motor case and allow the accumulated water to drain out. After draining the water, tighten the plug in the bottom and remove a similar plug on the side of the motor case. Unscrew the vent cap and pour a sufficient quantity of the recommended oil through this opening to bring the oil level up to the side opening. When the winch is subject to freezing temperatures: Allow the winch to remain idle long enough for the water content in the motor case to separate from the oil, but not long enough for it to freeze. Drain the water and replenish the oil as above. Should this procedure be impractical, drain the entire contents for the motor case immediately after operation ceases, and pour the oil back into the motor case before resuming operation. If not drained, a sufficient quantity of water will eventually accumulate so that the oil splasher will freeze fast. For temperatures 30° to 80°F (-1.1° to 26.6°C) use SAE 20 or 20W motor oil. For temperatures below 30°F (-1.1°C) use SAE 10 or 10W motor oil. For temperatures above below 80°F (26.6°C) use SAE 30 motor oil. ** CAUTION ** DO NOT LUBRICATE WHILE UNIT IS OPERATING
4. Check the air supply lubricator prior to running and during operation. Do not operate without oil in the lubricator as this may damage the air motor. The lubricator should be set at about 10-15 drops per minute. Fill the air motor with 30-wt. oil to maintain proper performance. Unscrew the bowl of the lubricator and fill the bowl with oil to the level indicated on the side of the bow. THE LUBRICATOR SHOULD BE CHECKED AND FILLED BEFORE THE BEGINNING OF A SHIFT OR BEFORE THE WINCH IS OPERATED. To properly adjust the lubricator turn the adjustment screw on the top of the lubricator to the right (CW) to completely close it. With the air winch drum rotating, turn the adjustment screw to the left (CCW) until the lubricator is dripping oil at the rate of six to eight drops per minute. Motor/Valve Chest: One the air motor valve chest, for the two (2) grease fitting (#14), requires only one (1) shot/pump of “General Purpose Grease” on monthly basis only. (NOTE: DO NOT OVER GREASE) Gear Reducer: The Air Power series of RAM Winch & Hoist Air Winches utilize the inside of the drum as the oil sump for the Planetary Gear Reducer that is enclosed with the winch’s drum. The unit is shipped with oil in the drum for the Gear Reducer. Therefore, it is not required to fill the drum with oil prior to starting up or commissioning the winch for the first time but should be checked as per start up requirements. The OUTBOARD Drum Flange (the side opposite the motor) has two plugged access ports located at 90 degrees to each other. To replace the gear oil, first drain the oil in the drum by rotating the drum so that one port is pointing down (Six O’clock) to act as a drain port and the other port is at (Three O’clock) to act as a vent port. Unscrew the port plugs to drain the oil. To fill the drum with new oil: Rotate the drum so that one port is pointing up (Twelve O’clock) to act as the fill port and the other port is at (Nine O’clock) to act as the Oil Fill Level Indicator Port. Pour oil into the Oil Fill Port until oil begins to drain from the Oil Level Indicator Port. When oil flows from the Oil Level Indicator Port cease filling the gear reducer oil sump with oil and plug both ports.
Be sure the Port Access Plugs are firmly tight before returning the winch to service. Drum Bearing Lubrication: The Drum is supported by twin taper roller bearing in the gear reducer on the motor side and by a spherical ball bearing enclosed in the out board winch frame. There is a grease zerk on the bearing cover (Item No.25) to facilitate greasing this bearing. LUBRICATION SCHEDULE LOCATION Gear Reducer Air Motor Outboard Drum Bearing Air Motor Lubricator
5.2.2
TYPE OF LUBRICANT Oil SAE 90 Wt Oil SAE 30 Wt Grease Oil SAE 10 Wt
REPLACEMENT SCHEDULE Once per Year As required by usage Every 200 hours of operation Daily or as required for heavy use
Cleaning The winch will last longer and be easier to maintain if it is kept relatively free of oil, dirt, and rust. Rinsing as often as possible with fresh water will help minimize corrosion.
5.2.3
Cables and Hoses All hose assemblies in service should be checked periodically for leaks, abrasions, kinks, cover blister or other damage. Assemblies showing signs of wear or damage must be replaced before they cause failure or create a hazard.
5.2.4
In Field Load Brake Adjustment Procedure
Please Note: The Preferred Method of adjusting an air winch or air hoists drum mounted band brake is with a suspended certified “test weight” or load. In the case of a Brake Band Replacement Done in the Field, this may not be possible. The following Procedure is provided to be able to properly adjust the automatic & manually operated brake bands. This procedure will test the winch brake against the motor torque.
THIS PROCEDURE IS TO BE PERFORMED WITHOUT A LOAD. MAKE SURE ALL PERSONNEL ARE CLEAR OF THE WINCH BEFORE BEGINNING! Perform the following steps: 1. Remove any suspended load from the winch cable. Be sure the cable is free to travel up and down for short distances without coming into contact with any rig personnel. 2. Disconnect the Air Line to the brake cylinder. Plug or cap this air line to prevent contamination. 3. Back out the brake band adjustment nut (See Item No. 9 – Fig. 2 Manual Brake Drawing and Item No. 11 – Fig. 3 Automatic Brake Drawing.) until the brake band is slightly loose on the drum’s braking surface. 4. Tighten the brake band adjustment nut until the brake band is snug against the drum and then tighten the nut three (3) more turns. 5. Slowly move the winch control valve in the payout direction or mode. If the drum starts to rotate, then stop the winch and tighten the brake band adjustment nut another turn. Caution: Do not tighten the brake adjustment more than one or two turns at a time. The adjustment nut should be tightened down to the point where the drum will not turn in the payout mode. The motor will stall at this time. Repeat this procedure with the manual band brake. Caution: Do not tighten the brake band adjustment nut beyond this point as it may cause the brake band to drag against the drum-braking surface in the payout mode. 6. Reconnect the automatic brake cylinder by reversing the steps outline in Step No. 2. 6.0
Component Removal / Replacement Maintenance of the winch consists of determining the defective part and removing and repairing or replacing that component. All work should be done only after the air supply is shut off and tagged Out of Service. If needed, consult with RAM Winch & Hoist or its nearest trained representative for service.
APPENDICES
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.
402006M
402006M
BILL OF MATERIALS “LIGHTNING” (HUR20), “MUSTANG” (HUR40), “CORSAIR” (HUR60) WINCH ASSEMBLY ITEM
QTY
1
1
PART NUMBER HUR-324-6 HUR-324-12 HUR-324-18 HUR-324-24 HUR-324-30 HUR-324-36
2 3 4
1 1 2
HUR-324-8DB HUR-324-14DB HUR-324-20DB HUR-324-26DB HUR-324-32DB HUR-502 HUR-503 HUR-004-6 HUR-004-12 HUR-004-18 HUR-004-20 HUR-004-30 HUR-004-36
5
6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 22
1
6 6 6 1
9 9 6 6 1 2 1 8 8 1 1 1 4
HUR-032-6 HUR-032-12 HUR-032-18 HUR-032-24 HUR-032-30 HUR-032-36 HUR-010 HUR-018 HUR-222 HUR20-A353 HUR40-A353 HUR60-A353 HUR-354 HUR-TAB HUR-355 24-741 HUR-506 HUR-016 QD4-A501 235-146 D10-322 HUD-895 QD4-545 HU-546A HU-548
DESCRIPTION Drum, ¯ 16 X 9 R.H. (Single Band Brake) 6” Between Flanges 12” Between Flanges 18” Between Flanges 24” Between Flanges 30” Between Flanges 36” Between Flanges Drum, ¯ 16 X 9 R.H. (Dual Band Brake) 8” Between Flanges 14” Between Flanges 20” Between Flanges 26” Between Flanges 32” Between Flanges Drive End Frame Bearing End Frame Frame Tie Bar 6” Between Flanges 8” or 12” Between Flanges 14” or 18” Between Flanges 20” or 24”Between Flanges 26” or 30” Between Flanges 32” or 36” Between Flanges Frame Tie Bar, Brake Mount 6” between Flanges 8” or 12” Between Flanges 14” or 18” Between Flanges 20” or 24” Between Flanges 26” or 30” Between Flanges 32” or 36” Between Flanges Tie Bar Flange Bolt Tie Bar O-Ring, Small Tie Bar O-Ring, Large Gear Box Assembly For Lightning For Mustang For Corsair Drum/Gear Box Hex Bolt Lock Washer Frame/Gearbox Hex Bolt Washer Interface Shaft Shaft Oil Seal Air Motor w/controls Frame/Motor Hex Bolt Lock Washer Bearing, Crank Motor End Valve Chest Valve Chest Cover Hex Head Capscrew
See Figure 1
WT (LBS) 209 252 294 337 380 422 312 355 398 441 483 211 150 16 21 26 32 37 42 16 21 26 32 37 42 3 0 0 95 95 95 2 0 2 0 3 1 120 2 0 1 24 1
BILL OF MATERIALS “LIGHTNING” (HUR20), “MUSTANG” (HUR40), “CORSAIR” (HUR60) WINCH ASSEMBLY CONTINUED 23
4
D02-321
ITEM
QTY
PART NUMBER
24 25 26 27 28 29 30 31 32 33
1 1 4 4 2 1 1 1 1 1
HUR-466 HUR-508 D02-354 D02-321 HUR-165 HUR-381 HUR-594 HUR-593 HUR-592 HUR-595
Lock Washer
DESCRIPTION Bearing Bearing End Cover Hex Head Capscrew Lock Washer Oil Hex Plug Rope Locking Wedge Drum/Gear Box Gasket Frame/Gear Box Gasket Frame/Motor Gasket Bearing End Cover Gasket
See Figure 1
0
WT (LBS) 2 3 1 0 0 1 0 0 0 0
BILL OF MATERIALS “LIGHTNING” (HUR20), “MUSTANG” (HUR40), “CORSAIR” (HUR60) MANUAL BRAKE ITEM 1 2
QTY 1 1
PART NUMBER
DESCRIPTION
WT (LBS)
HUR-715
Brake Handle Assembly
6
HUR-161
Mounting Bracket
5 1
3
1
K5UR-003
Sleeve Bearing
4
1
HUR-002
Retaining Ring
0
5
1
HUR-A152
¯16” Brake Band
25
6
2
HUR-162
Clevis Pin
1
7
4
D02-330
Cotter Pin
0
8
1
AG01505
Link Stud
1
9
1
D01-305
Nut
0
10
1
PDA312-24
Nut
0
See Figure 2
BILL OF MATERIALS “LIGHTNING” (HUR20), “MUSTANG” (HUR40), “CORSAIR” (HUR60) AUTO BRAKE ITEM
QTY
PART NUMBER
1
1
HUR-718
2
1
HUR-162-13
3
2
4
DESCRIPTION
WT (LBS)
Auto Brake Handle Assembly
6
Clevis Pin
1
FQ10405
Flat Washer
0
1
HUR-161
Mounting Bracket
5
5
1
HUR-003
Spacer
1
6
1
HUR-002
Retaining Ring
0
7
1
HUR-A152
¯16” Brake Band
25
8
2
HUR-162
Clevis Pin
1
9
6
DO2-330
Cotter Pin
0
10
1
AG01505
Link Stud
1
11
1
D01-305
Nut
0
12
1
PDA312-24
Nut
0
13
1
HUR-719
Rod End Clevis
2
14
1
HUR-720
Air Cylinder
22
15
1
HUR-726
Compression Spring
7
16
1
AG02757
Stop Tube For Brake Cylinder
7
17
1
AG70252
Quick Exhaust Valve
1
18
1
AG05316
Dust Excluder Valve
1
19
1
HUR-721
Auto Brake Bracket
10
20
1
HUR-162-2
Clevis Pin
0
21
1
HUR-162-1
Clevis Pin
0
22
4
HUR-330
Cotter Pin
0
23
2
FQ02017
Hex Head Capscrew
1
24
2
FQ10350
Flat Washer
0
25
2
D10-322
Lock Washer
0
26
2
FQ12300
Nut
0
See Figure 3
BILL OF MATERIALS “LIGHTNING” (HUR20), “MUSTANG” (HUR40), “CORSAIR” (HUR60) MANUAL AND AUTO BRAKE ITEM
QTY
PART NUMBER
DESCRIPTION
1
1
HUR-715
Brake Handle Assembly
6
2
2
HUR-161
Mounting Bracket
10
3
2
HUR-003
Spacer
2
4
2
HUR-002
Retaining Ring
0
5
2
HUR-A152
¯16” Brake Band
50
6
4
HUR-162
Clevis Pin
2
7
10
D02-330
Cotter Pin
0
8
2
AG01505
Link Stud
2
9
2
D01-305
Nut
0
10
2
PDA312-24
Nut
0
11
1
HUR-718
Auto Brake Handle Assembly
6
12
1
HUR-162-13
Clevis Pin
1
13
2
FQ10405
0
14
1
HUR-719
Flat Washer Rod End Clevis
5
15
1
HUR-720
Air Cylinder
22
16
1
HUR-726
Compression Spring
7
17
1
AG02757
Stop Tube for Brake Cylinder
7
18
1
AG70252
Quick Exhaust Valve
1
19
1
AG05316
Dust Excluder Valve
1
20
1
HUR-721DB
Auto Brake Bracket
10
21
1
HUR-162-2
Clevis Pin
0
22
1
HUR-162-1
Clevis Pin
0
23
4
HUR-330
Cotter Pin
0
24
2
FQ02017
Hex Head Capscrew
1
25
2
FQ10350
Flat Washer
0
26
2
D10-322
Lock Washer
0
27
2
FQ12300
Nut
0
See Figure 4
WT (LBS)
RECOMMENDED SPARES RECOMMENDED SPARES FORFOR STARNDARD HUR MODEL WITH MANUAL STANDARD HUR MODEL WITH MANUAL BRAKEBRAKE QTY
PART NO
DESCRIPTION
1
KU-940
Poppet Throttle Valve
1
HU-942
Poppet Throttle Valve Spring
1
HU-527
Large Valve Drive Pin
2
HU-627
Small Valve Drive Pin
1
HU-556
Throttle Lever
1
HU-567
Throttle Lever Latch Spring
1
HU-412
Throttle Lever Spring
1
HU-519
Crank Pin Sleeve
1
HU-518
Crank Valve End Bearing
2
HUD-895
Crank Pin End Bearing
1
HU-337-5
Piston Ring Set
1
HU-338-5
Oil Regulating Ring Set
5
HU-507
Cylinder Gasket
20
HU-504
Cylinder Washer
1
HUR-592
Motor Gasket
1
HUR-466
Drum Bearing
1
HUR-A152
1
107-151
1
HUR-158
Brake Adjusting Screw
1
HUR-016
Shaft Oil Seal
1
HUR-594
Gear/Drum Gasket
1
HUR-593
Gear/Frame Gasket
1
HUR-595
Bearing Cover/Frame Gasket
1
402171
Brake Band Brake Handle
Torque Hub Gasket
Recommended Spares for one (1) Year Foreign Operation. FOB: Houston, Texas – RAM Winch & Hoist Warehouse Terms of Payment: Net 30 Days
HU-501 D02-402 T1SE-368 D02-303A D02-421 D02-891 D02-889 6 CN D - 2 3 3 1 /2 D02-893 H5U5 4 5 BC HU-538 QD4-525S H5U-945S
1 2 3 4 5 6 7 8
KU-527 HU-527 HU-555A D02-553 HU-556 HU-869 HU-567 HU-842 HU-870 D02-524 K6U-412
26 27 28 29 30 31 32 33 34
35
25
23-188 D02-553 D02-402 H5U-546 HU-548 D02-321 KU-940 HU-942 D10-280 KU-943 H5UK744A H5U-526
14 15 16 17 18 19 20 21 22 23 24
11 12 13
9 10
Part Number
No.
1 2 1 1 1 1 1 1 1 2 1
1
2 1 2 1 4 4 1 1 1 1 1
2 1 1
1 1
Qty. (each) 1 2 1 1 1 1 1 1
Grease Fitting T h r o t t l e L e v e r S p r i n g Sto p P in Brake Inlet Plug Va l v e C h e s t C o v e r Va lv e Ch e s t S c r e w ½ ” L o c k Wa s h e r P o p p e t T h r o t t l e Va l v e P o p p e t T h r o t t l e Va l v e S p r i n g P o p p e t T h r o t t l e Va l v e B a l l P o p p e t T h r o t t l e Va l v e C a p Re v e r s e Va lv e f o r Win c h w ith A u t o ma t i c B r a k e Ro ta r y V a lv e f o r O v e r W in d in g W in c h L a r g e V a lv e D r iv e P in S ma ll V a lv e D r iv e P in Throttle Control Arm Throttle Lever Spring Stop Pin Throttle Lever Throttle Lever Latch Throttle Lever Latch Spring Throttle Lever Set Screw Throttle Lever Pin Throttle Lever Pin Cotter Throttle Lever Spring
Bu s h in g K e y R o ta r y Va lv e B u s h in g Re v e r s e Va lv e Bu s h in g
Ve n t Ca p Co tte r Va lv e Ch e s t Ba r e
Mo to r Ca s e D r a in P lu g 3 /8 ” P lu g Ve n t Ca p S-Hook Ve n t Ca p Ch a in Ve n t Ca p S c r e e n Ve n t Ca p S c r e e n Re ta in e r
Description
* *
*
48A 49 50 51 52 53 54 55 56 57 58
46 47 48
44 45
39 40 41 42 43
37 38
No.
RA M A ir Mo to r Tag R4 K - 3 0 2 RA M Q D 4
HU-518 HUD-895 RA M Q D 4 H505A HH5D-L505A HU-A513B HU-337-5 HU-338-5 HU-514 HU-507 D10-354 HU-504 HU-592 215-148 D10-322
HU-510 HU-511
HU-540 HU-541 HU-542 HU-519 HU-520 D02-317 D02-330 HU-509
Part Number
Motor Parts Listing
4 1
1
4 4 1 1 4 4 16 16 1 8 8
1 1 4
2 1
Qty. (each) 1 2 2 1 1 1 1 4
N a me p la te S c r e w Ba f f le f o r Mo to r Ca s e
Mo to r N a me p la te
Cylinder Sleeve P i s t o n A s s e mb l y Piston Ring (1 for each Piston) Oil Regulating Ring (1 for each Piston) P is to n W r is t P in Cylin d e r G a s k e t Cylinder Cap Screw (4 for each Cylinder) Cylinder Cap Screw Washer Motor Case Gasket Motor Case Screw 5 /8 ” L o c k W a s h e r
Cr a n k V a lv e E n d Be a r in g C r a n k P in E n d B e a r in g Cylin d e r H e a d
Co n n e c tin g Ro d Rin g Co n n e c tin g Ro d Bu s h in g
O il S p la s h e r O il S p la s h e r L o n g Riv e t O il S p la s h e r S h o r t Riv e t Cr a n k P in S le e v e Cr a n k L o c k P in Cr a n k L o c k P in N u t Cr a n k L o c k P in Co tte r Co n n e c tin g Ro d f o r H U R
Description
RAM P/N AH04401R
Double Reduction Wheel Drive
SERVICE MANUAL
RAM P/N AH004401R Double Reduction Wheel Drive
Parts Illustration 3 1 2 4 5 6
7
11
8
7 12 13
17 14 18
16
9
10
15
19
25
20 21
22 23
26 24 27 30 28
31 32
29
OPTIONAL
DISASSEMBLY OF WHEEL DRIVE 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 (28) if necessary. STEP 4 Remove bolts (26) and large cover (25). Disengage plunger (23) usually remains with large cover (25). Remove disengage plunger (23) and “O” ring (24) from cover on end of input shaft (2). The thrust washer (22) will usually remain in position on thrust face of large cover (25). STEP 5 Remove primary sun gear (20) and thrust washer (21), used in aluminum cover units only, from end of input shaft (2). STEP 6 Remove the primary carrier assembly (19). STEP 7 Remove the secondary carrier assembly (18). It may be necessary to remove the ring gear (17) first, if difficulty is encountered removing the carrier. STEP 8 Remove the input shaft (2) from spindle (3). Remove the retaining rings (14), washer (15), and spring (16) from input shaft (2) only if replacement is required. STEP 9 Remove the 6 or 12 bolts (9) and washers (10) from hub (11) and remove ring gear (17). It may be necessary to strike ring gear (17) with a rubber mallet to loosen from hub (11). STEP 10 Remove the retaining ring (13) from in front of the bearing cone (12) and lift hub (11) from spindle (3). If bearings are not loose fit, it may be necessary to press spindle (3) from hub (11). Note: Use a retaining ring expander tool to remove retaining ring (3). STEP 11 Remove the oil seals (4) and (5) and bearing cones (6 & 12) from hub (11). Inspect bearings cups (7) in position and remove only if replacement is required.
RAM P/N AH004401R Double Reduction Wheel Drive
Parts Illustration 3 1 2 4 5 6
7
11
8
7 12 13
17 14 18
16
9
10
15
19
25
20 21
22 23
26 24 27 30 28
31 32
29
OPTIONAL
ASSEMBLY OF WHEEL DRIVE Refer to Parts Illustration
STEP 1 Press new bearing cups (7) in each side of the hub (11). It is recommended that bearing cups (7) and cones (6 & 12) be replaced in sets. STEP 2 Assemble bearing cone (6) into cup (7) at seal end of hub (11) and press a new seal (5) into hub (11). Install boot seal (4) on hub (11) if unit is so equipped. STEP 3 Position spindle (3) upright on bench. Lubricate lips of seal (4) and (5) and lower hub (11) onto spindle (3). Hub (11) should be centered as it is lowered over spindle (3) to prevent seal damage. STEP 4 Assemble bearing cone (12) over spindle (3) and into bearing cup (7). If bearings (6,7, & 12), hub (11) or spindle (3) is replaced, a new retaining ring (13) is required for proper bearing setting. Do not re-use snap ring after is has been installed and removed from unit. Select the thickest retaining ring (13) that can be assembled into the ring groove of the splined end of spindle (3) above bearing cone (12). Bearing should have from .000-.006 inches (.00.15mm) of end play when proper retaining ring (13) is installed. STEP 5 Assemble a retaining ring (14) in groove opposite pilot end of input shaft (2). Assemble a washer (15), spring (16), a second washer (15), and a second retaining ring (14) in the middle grooves of input shaft (2). Some shafts should have and require only one retaining ring (14). STEP 6 Assemble the splined end of the input shaft (2) down into spindle (3). STEP 7 Assemble the secondary carrier assembly (18) to spindle (3) at splines. STEP 8 Clean mating surfaces and apply a bead of silicone sealant to face of hub (11) that mates with ring gear (17) (See instructions on sealant package). Hub (11) is attached ring gear (17) with 6 or 12 3/8-24 grade 8 hex head cap screws (9) and flat washers (10). Torque cap screws to 52 – 60 lb. Ft. (70 – 81 Nm). STEP 9 Assemble the primary carrier assembly (19) into the ring gear (17). It will be necessary to rotate carrier to align secondary sun gear {part of primary carrier assembly (19)} with planet gear teeth in secondary carrier assembly (18). Assemble primary sun gear (20) over input shaft (2). Rotate primary sun gear (20) to align input shaft (2) to gear splines and gear teeth in primary carrier assembly (19). STEP 10 For units with the aluminum cover (25) assemble the small thrust washer (21) over input shaft (2) and against shoulder of input shaft (2).
RAM P/N AH004401R Double Reduction Wheel Drive
Parts Illustration 3 1 2 4 5 6
7
11
8
7 12 13
17 14 18
16
9
10
15
19
25
20 21
22 23
26 24 27 30 28
31 32
29
OPTIONAL
ASSEMBLY OF WHEEL DRIVE Refer to Parts Illustration
STEP 11 For units with the aluminum cover (25), lubricate “O” ring (24) and assemble in grooves of the disengage plunger (23). Assemble disengage plunger (23) over end of input shaft (2) and against thrust washer (21). For units with cast iron cover (25), lubricate “O” ring (24) and assemble in groove inside cover hole, push plunger (230 into cover with pointed end facing inside of unit. STEP 12 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 face of ring gear (17). Assemble cover (25) aligning holes of cover and ring gear. Assemble the eight 5/16 – 18 x 1 inch hex head bolts (26). Torque bolts to 20 – 25 lb. Ft. (27 – 34 Nm). STEP 13 Assemble the disengage cover (28) with dimpled center protruding out if wheel is to be used to drive the vehicle. Assemble and torque the two 5/16 – 18 bolts (29). Torque bolts to 10 – 20 lb. Ft. (13 – 27 Nm). STEP 14 Invert the Wheel Drive assembly and assemble the coupling (1) with counter bore out to the input shaft (2). STEP 15 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 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 Wheel Drive.
LUBRICATION RECOMMENDATIONS
IMPORTANT: WHEEL 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 Wheel Drive under normal temperature ranges between 0 – 120°F (-18 to 49°C). Wheel Drive 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.
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.
RAM P/N AH004401R Double Reduction Wheel Drive
Parts Illustration 3 1 2 4 5 6
7
11
8
7 12 13
17 14 18
16
9
10
15
19
25
20 21
22 23
26 24 27 30 28
31 32
29
OPTIONAL
PARTS LISTING Refer to Parts Illustration Drawing for Item Numbers Item No. 1 2 3 4 5 6 7
Description
Coupling Input Shaft Spindle Boot Seal 604401 Oil Seal 14-00-044-010 Bearing Cone 04-01-101-35 Bearing Cup 04-01-102-12
8 9 10 11
Wheel Bolt Hex Head Bolt (Grade 8) Flat Washer Hub
12 13
Bearing Cone 04-01-101-17 Retaining Ring Kit 14-02410-003 Retaining Ring Washer Disengage Spring Ring Gear
14 15 16 17
No. Used in Ass’y. 1 1 1 1 1 1 2
Item No. 18 19 20 21 22 23 24
9 6-12 6-12 1
25 26 27 28
1
29 30
Description Secondary Carrier Assembly Primary Carrier Assembly Sun Gear Thrust Washer Thrust Washer Disengage Plunger 610801 “O” Ring Cast Iron Cover 614101 Aluminum Cover 10-00-141113 Large Cover Hex Head Bolt Magnetic Plug 14-00-052-002 Disengage Cover 14-02-039005 Hex Head Bolt Quick Disconnect Gasket
31 32
Quick Disconnect Assembly Hex Head Bolt
2 2 1 1
No.Used in Ass’y. 1 1 1 1 1 1 1
Contact RAM Winch & Hoist at (281) 999-8665 with model number, item number and description to obtain the appropriate parts. Refer to parts listing for the specific item numbers and quantities.
Wheel Drive Service Kits Part No.
Description
Included Items
14-02-410-003 641008** 641017**
Retaining Ring Kit Bearing and Seal Kit Seal Kit
13 (7 Retaining Rings) 5, 6, 7, 12, 13 and 24 5,13 and 24
** Indicates kit also includes a tube of sealant, part number 604101.
1 8 1 1 2 1 1 2
Component Data Sheets
RAM P/N AG35139 Air Cylinder
RAM P/N AG35139 Air Cylinder
A
RAM P/N AG70252
HUR40 AIR WINCH RAM WINCH & HOIST 10/06 12/05
