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17 WINCH OPERATING PRACTICES 1. Read the manufacturer's instructions before operating the winch. 2. Always inspect, test maintain and operate this winch in accordance with American National Standards Institute Safety Standards B Never Lift a load greater than the rated line pull of the winch. 4. Use the recommended size wire rope for load to be handled. 5. Never use the wire rope as a sling. 6. Always stand clear of the load. 7. Never use the winch for lifting or lowering people, and never stand on a suspended load. Unless winch is designed for personnel handling. 8. Never carry loads over people. 9. Never disengage the clutch with a load applied to the winch. 10. Never engage the clutch with the winch motor running. 11. Always rig the winch properly and carefully, making certain the wire rope is properly anchored to the drum. 12. 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. 13. Never operate a winch with a twisted, kinked or damaged wire rope. 14. Periodically inspect the winch thoroughly and replace worn or damaged parts. Keep accurate records of all inspections and repairs. 15. Follow the lubrication instructions provided by the manufacturer. 16. 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. 17. Keep the rope clean and well lubricated. Replace wire rope that is frayed. 18. Ease the slack out of the wire rope when starting. Do not jerk the winch. 19. If the drum is exposed to personnel walkways, place a guard over the drum. 20. Do not use your hands to guide the rope onto the drum when winding in the wire rope. 21. Be certain there are no objects in the way of the load or hook when operating the winch. 22. Do not use higher air pressure than recommended by the manufacturer. 23. 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. 24. Wear proper clothing to avoid entanglement in rotating machinery. 25. Be certain the air supply is shut off before performing maintenance on the winch. 26. Properly secure a winch before leaving it unattended. 27. Do not leave a load suspended for any extended period of time. Never leave a suspended load unattended. 28. Do not allow unqualified personnel to operate a winch. 29. Do not operate a winch if you are not physically fit to do so. 30. Do not divert your attention from the load while operating a winch. 31. 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. 32. Do not force a hook into place by hammering. 33. Never operate a winch beyond the point where less than four wraps of wire rope remain on the drum. 34. Do not use the wire rope as a ground for welding. Do not attach a welding electrode to a winch or sling. 35. Never operate a winch that makes excessive mechanical noise. Report the problem immediately. Post at Operating Station Form 2008

23 ! WARNING DO NOT OPERATE WITHOUT GUARDS IN PLACE! FAILURE TO DO SO COULD RESULT IN INJURY.

25 ! 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)

27 DO NOT ADD AN EXTERNAL LUBRICATOR TO THIS WINCH. THERE IS ONE CONTAINED INSIDE THE CONTROL HOUSING. Handle Position Emergency Air Supply Handle Position Normal Air Supply WARNING CYLINDER IS SPRING LOADED FILTER DO NOT ADD OIL LUBRICATOR USE 30wt OIL

39 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. Once the above items are completed, you may proceed to slowly open the air supply by opening the emergency stop valve (see drawing M item L ). Slowly open the valve and listen for any leaks. 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. When the override is depressed, you will hear the poppet valve (see drawing M item K ) shift and you should then get pressure to the regulator. If there is still escaping or exhausting air, check the emergency stop on the control panel. This is the red palm button. It should be in the up position. You may want to disconnect 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 gauge on the regulator. NOTE: This is the regulated pressure, not the main supply pressure. The winch controls are non-operable and must not be played with as movement of the control valve will cause the brake to release and the winch drum will rotate. The winch may now be operated to verify proper operation. If there is wire rope on the winch drum, care must be taken to prevent damage to the rope, the winch 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.

46 4.5 EMERGENCY OPERATION PROCEDURE This winch is equipped with emergency raise and lower capability. The primary or preferred method is to connect a stored supply of air or nitrogen gas to the unit via the air supply inlet valve, which has a connection for this. This is a 3-way selector valve to allow ease of shifting. PRIMARY EMERGENCY CONTROL With stored air or nitrogen supply connected, make sure the winch control valve is in center or neutral position. Shift the air supply inlet valve handle from normal position to emergency supply position. The winch will operate as normal in this mode as long as there is at least 70 psi of supply pressure. DO NOT ATTACH ANYTHING TO THE AUTO BRAKE RELEASE LEVER TO HOLD IT OPEN OR RELEASED. CONTROL IT BY HAND ONLY.! WARNING! THIS PROCEDURE SHOULD BE CONDUCTED BY A TRAINED OPERATOR ONLY. FAILURE TO CONTROL THE LOAD PROPERLY COULD CAUSE SEVERE INJURY OR DEATH. SECONDARY EMERGENCY CONTROL This will allow lowering only. The operator must be trained to use this mode. The manual caliper brake is used in conjunction with the release of the auto band brake. Squeeze the handle of the caliper brake to set and while holding this brake on, slowly release the auto band brake as shown in Fig. 4. You will be able to partially release your grip on the caliper brake and with the auto brake off; the load should begin to lower. The amount of grip or squeeze on the caliper will control the descent speed rate. KEEP THE DESCENT RATE UNDER CONTROL AT ALL TIMES! DO NOT COMPLETELY RELEASE YOUR GRIP ON THE MANUAL CALIPER BRAKE!

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RAM P/N AG04717 E-Stop Valve System Pressure 0-150 psi (0-10 bar) Allowable Backpressure at exhaust port 0 Materials Valve body and caps: 316 Stainless steel (NACE Standard MR- 01-75) Valve

107 RAM P/N AG04717 E-Stop Valve System Pressure psi (0-10 bar) Allowable Backpressure at exhaust port 0 Materials Valve body and caps: 316 Stainless steel (NACE Standard MR ) 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) Weight lbs (.45 kg)

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ACCESSORIES SHUTTLE VALVES a range of Shuttle Valves in different sizes, made from Brass or 316 Stainless Steel General Description VERSA Shuttle Valves are constructed of solid Brass or 316

A typical schematic is shown below: Materials 1 2 3 Type: Brass Stainless Steel Body: Brass 316 Stainless Steel Shuttle: Nylon(Zytel) 316 Stainless Steel Seals: NBR (Nitrile) FKM (Fluorocarbon)

111 ACCESSORIES SHUTTLE VALVES a range of Shuttle Valves in different sizes, made from Brass or 316 Stainless Steel General Description VERSA Shuttle Valves are constructed of solid Brass or 316 Stainless Steel, with resilient seals providing tight shut off. Shuttle valves are 3/2 valves, primarily used to charge and discharge a pressure line or chamber from two - or more - sources. A typical schematic is shown below: Materials Type: 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 Functional Description Shuttle Valves have a free moving shuttle that blocks one of two inlet ports while the other inlet port is connected to the (common) outlet port. When a pressure signal enters the port blocked by the shuttle, it will cause the shuttle to shift over to close the opposite inlet port. The shuttle will stay there while the line or chamber connected to the outlet port is charged and/or discharged and will only shift when pressure is applied to the inlet port it is blocking at that time. In logic terms a shuttle valve is an 'OR' - function. Pressures Pressure range Pneumatic: 5 to 200 psi (0.35 to 14 bar) Hydraulic: 5 to 500 psi (0.35 to 35 bar) Symbol Mounting IN OUT IN Preferably 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. steel 1/8 NPT SV (51) 1.5 (38) 1.0 (25) 0.8 (12) 0.57 (0.26) 1/4 NPT SV-3 SV (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 (64) 1.9 (48) 1.3 (32) 1.6 (23) 1.10 (0.50) 1/2 NPT SV (64) 1.9 (48) 1.3 (32) 2.1 (30) 1.10 (0.50) 3/4 NPT SV (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

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113 RAM P/N AG00144 POPPET VALVE Basic Size 1 Port Size 1 Operating Pressure psig (bar) (0-20.7) Pilot Pressure psig (bar) ( ) Weight lbs. (kg) 3.69 (1.68)

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115 RAM P/N AG04714R MANUAL CONTROL VALVE 4 Way 3 Position Manual Control Valve Body Assembly 1 ¼ Ports Hand Lever Assembly SA For 1 ¼ Valves Spring-Center Cap Assembly

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117 RAM P/N AG00146 RAM P/N AG00152

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123 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: PSI (Adjustable) eclass: Feature: PSI (Adjustable) UNSPSC Code:

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125 RAM P/N AG00180 Flow Control Valve

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129 Hydraulic Apply Sliding Caliper Disc Brakes Installation and Service Instructions HYDRAULIC APPLY Sliding Caliper Disc Brakes Disc Brake Linings do not contain asbestos. Brake lining compounds do, however, contain elements that may become airborne during the life of the lining. To prevent any health problems associated with lining dust, we suggest ventilators be installed as needed on enclosed or stationary equipment. A Material Safety Data Sheet is available upon request. When installing these brakes, it is of utmost importance to maintain parallelism between mounting bolts and that caliper be centered evenly and squarely over disc. This will prevent binding of caliper and ensure even lining to disc contact. MOUNTING PROCEDURE 1. Using Figure 1 and Table 2, determine A dimension and locate caliper mounting holes. 2. Distance from mounting surface to head of mounting bolt is 82.6 mm (3.25") regardless of disc thickness. 3. Mount brake on disc and bolt securely to vehicle or machine using grade 5 or better mounting bolts or pins. DISC CENTERLINE TO MOUNTING HOLE DIMENSION millimeters inches DISC DIA. A DIM mm (6") 85.9 mm (3.38") mm (8") mm (4.38") mm (10") mm (5.38") mm (12") mm (6.38") mm (14") mm (7.38") mm (16") mm (8.38") mm (18") mm (9.38") mm (20") mm (10.38") TABLE 2 For disc diameters greater than mm, add 9.7 mm (20", add.38") to disc radius to obtain A dimension.

130 HYDRAULIC CONNECTION & ADJUSTMENT PROCEDURE (Refer to Figure 3) Port Size: 1/8-27 NPTF 1. Thread in brake module housing (2) until a total clearance of approximately.30 mm (.012") is obtained between disc and linings. NOTE: Make sure piston (5) is bottomed out in brake module housing (2). 2. Back off brake module housing (2) as required to position ports in vertical alignment. 3. Tighten set screw (8). 4. Move bleeder screw (1) to higher of two ports for ease of bleeding. Torque bleeder screw (1) N-m (12-14 lb-ft). 5. Install hydraulic line in lower port. 6. Bleed system making sure all air is eliminated. During the bleeding process for these brakes, hydraulic pressure should not exceed 13.8 bar (200 psi). 7. Apply rated hydraulic pressure and check for leaks. CHANGE SEAL PROCEDURE (Refer to Figures 3 & 4) See Table 1 for Repair Kit required for your brake. 1. Disconnect necessary fluid line from brake and remove caliper from vehicle or machine. Cap end of fluid line to prevent entry of dirt into hydraulic system. 2. Remove set screw (8) from housing (11) and remove brake module housing (2) from housing (11). 3. Place brake module housing (2) face down on bench, support brake module so piston (5) can be eased out of bore. This is accomplished by carefully introducing low air pressure, bar (10-15 psi), through the hydraulic line port. Do not use high pressure as it is dangerous and unnecessary. Use just enough air pressure to ease the piston out of the bore. Do not blow piston out of the bore. If the piston is seized or cocked or does not come out readily, release the air pressure and use a soft (brass) hammer to rap sharply on and around the end of the piston. Reapply air pressure to remove the piston. 6. Carefully install new o-ring (3) and new back-up ring (4) on piston (5). Note order of back-up ring and o-ring. 7. Lubricate piston (5) with clean type system fluid and install in brake module housing (2). Note direction of piston and be sure it is bottomed out in brake module. 8. Thread brake module housing (2) into housing (11) until a total clearance of approximately.30 mm (.012") is obtained between disc and linings. 9. Back off brake module housing (2) as required to position ports in vertical alignment. 10. Insert new nylon plug (7) into set screw (8) hole. Install nylon plug (7) even if originally not included on your model. 11. Install and tighten set screw (8). 12. Move bleeder screw (1) to higher of two ports for ease of bleeding. Torque bleeder screw (1) N-m (12-14 lb-ft). 13. Install hydraulic line in lower port. 14. Bleed system making sure all air is eliminated. Apply hydraulic pressure and check for leaks. CHANGE LINING PROCEDURE (Refer to Figure 3) See Table 1 for Lining Kit required for your brake. Lining assemblies (10) can be replaced without removing brake module housing (2). 1. Remove cap screw (6) and spring clip (9); allow lining assemblies (10) to drop out of housing (11). NOTE: On small diameter discs with large hubs, it may be necessary to remove one mounting bolt and swing housing aside to free lining assemblies. Earlier models used a compression spring which is not included in the lining kit. 2. Make sure piston (5) is bottomed out in brake module housing (2). Loosen set screw (8) and thread brake module housing (2) out of housing (11) so piston (5) is flush with housing (11). 3. Install new lining assemblies (10) in housing (11). 4. Install new spring clip (9) and cap screw (6) and torque N-m (10-12 lb-ft). NOTE: If the lining kit does not include new spring clip (9) reinstall compression spring. 5. To continue, refer to HYDRAULIC CONNECTION & ADJUSTMENT PROCEDURE Section. 4. Remove o-ring (3) and back-up ring (4) from piston (5). NOTE: Be careful not to scratch or mar piston. 5. Clean all parts thoroughly and lubricate all rubber components from Repair Kit with clean type fluid used in the system.

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AIR WINCH MODEL HU40 / HUL40

Instructions, Parts and Maintenance AIR WINCH MODEL HU40 / HUL40 14603 CHRISMAN HOUSTON, TEXAS 77039 (281) 999-8665 FAX: (281) 999-8666 or (888) 726-5438 Warning Tags Safety Guidelines Winch Operating