Instructions, Parts and Maintenance Manual AIR WINCH MODEL K6UL K6UL35WF TRANSOCEAN OFFSHORE P.O. GLOBE-0000380836 RAM Job# RS8839 S/N??????? 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. 4603 CHRISMAN HOUSTON, TEXAS 77039 (8) 999-8665 FAX: (8) 999-8666 or (888) 76-5438
Warning Tags Safety Guidelines Winch Operating Practices.0 General Information Page of TABLE OF CONTENTS. User Responsibility and Safety Precaution. Introduction.. Purpose.. Model Number, Serial Number, and Options..3 Warranty.3 Equipment Description.3. Capabilities and Limitations.3. Specification and Descriptive Data.0 Functional Description. Major Assembles.. Drive Assembles 3.0 Installation Instructions 3. Site Selection 3. Handling 3.3 Installation Procedures 3.3. Welding/Bolt Down 3.3. Requirements Prior to Start Up 3.4 Installation Checkout 3.4. Phase- Installation Inspection 3.4. Phase- Start Up and Preliminary Test
3.5 Cable Installation Contents to be continued Page of 3.5. Cable Termination on Drum 3.5. Spooling Cable onto Drum 4.0 Operating Instructions 4. Operator Start Up 4. Shutdown 4.3 Brake Release Valve 5.0 Preventive Maintenance 5. Introduction 5. Maintenance Plan 5.. Lubrication Schedule 5.. Cleaning 5..3 Cable and Hoses 5..4 Brake Adjustment 5..5 General Inspection 5..6 Bushing Replacement 6.0 Component Removal/Replacement Appendices RAM Winch & Hoist Parts Information K6UL Utility Rating Performance Characteristics K6UL General Assembly Manual Brake Drawing K6UL General Assembly Auto Brake Drawing K6UL-0AM General Arrangement K6UL-0AM General Arrangement K6UL-4AX General Arrangement K6UL-0AM37 Pendant Control K6UL Parts Illustration Sheet K6UL Parts Illustration Sheet K6UL Auto Band Brake Parts Illustration K6UL Disengaging Clutch Parts Illustration K6UL Remote Control Parts Illustration K6UL Parts List K6UL Air Schematic K6UL Drum Guard Arrangement Drawing K6UL Recommended Spare Parts List Component Data Sheets
There is a bleeder valve adjustment on the side of the housing that holds the release valve. The valve is set at the factory, but after time and with continuous use, the valve may require some adjustment. This bleeder valve sets the rate at which the brake is released. This gives the winch precise spotting control in the payout mode with rated load. When the valve handle is in the center position, there should be no air coming out of the release valve to the brake. If there is even a small amount going to the brake, this will prevent the quick exhaust from exhausting the brake air and allowing the brake to set. Adjustment is trial and error and should be done in small increments. If it is adjusted too far, the brake will not release or will release too fast. 5.0 Preventative Maintenance 5. Introduction This section gives necessary information for periodic and preventive maintenance, and for some repairs or replacements. For further information, service assistance or problems, call RAM Winch & Hoist Service Department. 5. Maintenance Plan 5.. Lubrication Schedule Under normal operating conditions on a permanent installation, the following lubrication schedule is recommended:. The gear reducer is filled with grease (Citgo Lithoplex RT-NLGI No. or equal) at the factory. After 500 hours of operation, remove ¼ plug on gear case and check. If unit needs more grease then add thru this hole.. Lubricate the bearings with Citgo Lithoplex RT-NLGI No. or equal 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 in 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 and the oil splasher will freeze fast. For temperatures 30 to 80 F (-. to 6.6 C) use SAE 0 or 0W motor oil. For temperatures below 30 F (-. C) use SAE 0 or 0W motor oil. For temperatures above 80 F (6.6 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 0-5 drops per minute. LUBRICATION SCHEDULE LOCATION TYPE OF LUBRICANT REPLACEMENT SCHEDULE Gear Reducer (Citgo Lithoplex RT-NLGI Once per Year No. or equal) Air Motor Oil SAE 30 Wt As required by usage Outboard Drum Bearing (Citgo Lithoplex RT-NLGI Every 00 hours of operation No. or equal) Air Motor Lubricator Oil SAE 0 Wt Daily or as required for heavy use 5.. Cleaning The winch will last longer and 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..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..4 Brake Adjustment To adjust the brake, rotate the Brake Adjusting Nut (7). Threading the nut further down the Brake Adjusting Screw (6) tightens the brake; backing the nut off loosens the brake.
APPENDICES RAM Winch & Hoist Parts Information K6UL Utility Rating Performance Characteristics K6UL General Assembly Manual Brake Drawing K6UL General Assembly Auto Brake Drawing K6UL-0AM General Arrangement K6UL-0AM General Arrangement K6UL-4AX General Arrangement K6UL-0AM37 Pendant Control K6UL Parts Illustration Sheet K6UL Parts Illustration Sheet K6UL Auto Band Brake Parts Illustration K6UL Disengaging Clutch Parts Illustration K6UL Remote Control Parts Illustration K6UL Parts List K6UL Air Schematic K6UL Drum Guard Arrangement Drawing K6UL Recommended Spare Parts List
8 7 NOTES:. WEIGHT OF UNIT W/O WIRE ROPE IS,900 LBS.. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED. 3. UTILITY CONSUMPTION IS 350 CFM AT 90 PSI FOR FULL RATED PERFORMANCE. 4. REMOTE CONTROL NOT SHOWN. 6 5 9 /6 DRUM q 6 7/6 DRUM q D D 4 n TYP 3 REVISION HISTORY REV DESCRIPTION DATE ECN 0 INITIAL RELEASE 0//03 NA 3 /4 / 6 3/4 / 7/8 3 37 3/4 VIEW A-A C 63 3/6 C CVP REMOTE 4 5/6 CONTROL MANIFOLD Ø-/ REGULATOR Ø-/ FILTER Ø-/ LUBRICATOR EMERGENCY STOP BALL VALVE 0 DRUM WIDTH DRUM q AUTOMATIC BAND BRAKE n 3/4 DRUM 43 /6 CG CG Ø 4 /4 DRUM FLANGE B B 8 9/6 q 9 7/8 CG /8 Ø-/ NPT AIR INLET 5/8 q /8 CG Ø-/ NPT MUFFLER 3/6 Ø-/ NPT AIR INLET A A 7 /6 CG 7/8 Ø-/ NPT AIR INLET 3 /4 MANUAL BAND BRAKE AUTOMATIC BAND BRAKE 0//03 A ANGLES: ±0.5 DIMENSIONS: A EST. FINISHED SURFACE WEIGHT SEE NOTES LBS. TITLE: FINISH: 5 ORIGINAL JOB NO. TBD 8 7 6 4 3/8 Ø-/ NPT EXHAUST 5 9 /6 DRUM q 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 () ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; () NOT LOAN, REPRODUCE, EXHIBIT OR DISTRIBUTE 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. 4 3rd ANGLE PROJECTION DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS STATED ON ALL MACHINED SURFACES X.X ±0.03 X.XX ±0.05 X.XXX ±0.005 FRACTION ± /6 SURFACE FEATURES: MACHINED PARTS ONLY T.I.R t.005 PERPENDICULAR b.05 FLATNESS.00 PARALLEL f.05 BREAK ALL SHARP EDGES 3 DWN: CKD: ENG: W. CULBERTSON M. WEHMEYER M. WEHMEYER APVD: M. WEHMEYER NA NEXT ASSEMBLY 0//03 0//03 0//03 K6UL-0AM MODEL NUMBER SIZE: PART NUMBER: B GENERAL ARRANGEMENT, K6UL-0AM W/ CVP REMOTE CONTROL MANIFOLD NA S00789 DWG NUMBER: REV: SCALE: SHT: NTS OF 0
8 NOTES:. WEIGHT OF UNIT W/O WIRE ROPE IS APPROXIMATELY 900 LBS.. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED. 3. UTILITY CONSUMPTION IS 350 CFM AT 90 PSI FOR FULL RATED PERFORMANCE. 7 6 5 9 /6 DRUM C 6 7/6 L 4 L DRUM C TYP. 3 REVISION HISTORY REV DESCRIPTION DATE ECN 0 INITIAL RELEASE /9/03 - D D 3 /4 / 6 3/4 / 7/8 3 37 3/4 VIEW A-A 69 5/8 AUTOMATIC BAND BRAKE MANUAL BAND BRAKE Ø / LUBRICATOR C 4 /8 C Ø / FILTER 0 Ø / REGULATOR DRUM WIDTH Ø / REGULATOR DRUM C L Ø 3/4 DRUM Ø4 CG CG CG DRUM FLANGE 33 /6 8 / C L 7 5/6 CG 9 / Ø / NPT AIR INLET B B /6 CG 5/8 C L 7 5/8 Ø NPT MUFFLER 4 9/6 Ø NPT EXHAUST A A 7 3/6 CG 3 /4 AUTOMATIC BAND BRAKE 3/6 Ø / NPT AIR INLET 9 /6 DRUM C L /9/03 A ANGLES: ±0.5 DIMENSIONS: A EST. FINISHED SURFACE WEIGHT SEE NOTES LBS. TITLE: FINISH: 5 ORIGINAL JOB NO. TBD 8 7 6 5 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 () ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; () NOT LOAN, REPRODUCE, EXHIBIT OR DISTRIBUTE 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. 4 3rd ANGLE PROJECTION DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS STATED ON ALL MACHINED SURFACES X.X ±0.03 X.XX ±0.05 X.XXX ±0.005 FRACTION ± /6 SURFACE FEATURES: MACHINED PARTS ONLY T.I.R.005 PERPENDICULAR.05 FLATNESS.00 PARALLEL.05 BREAK ALL SHARP EDGES 3 DWN: CKD: ENG: E. SOESANTO M. WEHMEYER M. WEHMEYER APVD: M. WEHMEYER NA NEXT ASSEMBLY /9/03 /9/03 /9/03 K6UL-0AM MODEL NUMBER SIZE: PART NUMBER: B GENERAL ARRANGEMENT, K6UL-0AM NA S00793 DWG NUMBER: REV: SCALE: SHT: NTS OF 0
8 NOTES:. WEIGHT OF UNIT W/O WIRE ROPE IS APPROXIMATELY 900 LBS.. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED. 3. UTILITY CONSUMPTION IS 350 CFM AT 90 PSI FOR FULL RATED PERFORMANCE. 7 6 5 7 /6 DRUM C 4 7/6 L 4 DRUM C L TYP. 7/8 3 REVISION HISTORY REV DESCRIPTION DATE ECN 0 INITIAL RELEASE /9/03 - D D 3 /4 / 6 3/4 / 3 37 3/4 VIEW A-A AUTOMATIC BAND BRAKE C C Ø / LUBRICATOR Ø / FILTER 69 5/6 4 3/8 AUTOMATIC BAND BRAKE Ø / REGULATOR Ø / REGULATOR 3 7/8 DRUM WIDTH DRUM C L Ø 3/4 DRUM CG 4 CG DRUM FLANGE CG 33 /6 B B 8 / C L 7 /6 CG 9 5/6 Ø / NPT AIR INLET /9/03 A ANGLES: ±0.5 DIMENSIONS: A EST. FINISHED SURFACE WEIGHT SEE NOTES LBS. TITLE: FINISH: 5 ORIGINAL JOB NO. TBD 8 5/8 C L 3/8 CG 7 7 5/6 Ø / NPT AIR INLET Ø NPT MUFFLER 6 9/6 Ø / NPT AIR INLET 4 / Ø NPT EXHAUST 5 A A 7 /6 DRUM C 7 3/4 CG L 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 () ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; () NOT LOAN, REPRODUCE, EXHIBIT OR DISTRIBUTE 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. 4 3rd ANGLE PROJECTION DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS STATED ON ALL MACHINED SURFACES X.X ±0.03 X.XX ±0.05 X.XXX ±0.005 FRACTION ± /6 SURFACE FEATURES: MACHINED PARTS ONLY T.I.R.005 PERPENDICULAR.05 FLATNESS.00 PARALLEL.05 BREAK ALL SHARP EDGES 3 DWN: CKD: ENG: E. SOESANTO M. WEHMEYER M. WEHMEYER APVD: M. WEHMEYER NA NEXT ASSEMBLY /0/03 /9/03 /9/03 K6UL-0AM MODEL NUMBER SIZE: PART NUMBER: B 3 /4 GENERAL ARRANGEMENT, K6UL-4AX NA S0079 DWG NUMBER: REV: SCALE: SHT: NTS OF 0
K6U PARTS LIST Item No. Description of Part Unit Total Part Number Item No. Description of Part Unit Total Part Number Motor Assembly K6U-A50 40 Rotary Valve Bushing K6U-55S Motor Case K6U-50 4 Bushing Key HU-538 Drain Plug D0-40 4 Reverse Valve Bushing K6U-945S 3 Vent Cap D0-303A 43 Throttle Lever Spring Stop Pin D0-553 4 Vent Cap Cotter D0-893 44 Rotary Valve K6U-56 5 Vent Cap Chain D0-89 45 Rotary Valve Key K6U-57 6 S-Hook D0-4 46 Rotary Valve Key Screw 4E-638 7 Vent Cap Screen D0-889 47 Valve Key Screw Lock Washer 4U-58 8 Vent Cap Screen Retainer 6CND-33-/ 48 Reverse Valve Assembly K6U-K744A 9 Throttle Lever HU-556 Reverse Valve O-Ring R8-3 0 Throttle Lever Latch HU-869 49 Throttle Valve Ball K6U-94 Latch Spring HU-567 50 Throttle Valve K6U-940 Throttle Lever Set Screw HU-84 5 Throttle Valve Face K6U-59 3 Throttle Lever Spring K6U-4 5A Throttle Valve Face Spacer K6U-80 4 Throttle Lever Pin HU-870 5 Throttle Valve Face Cap K6U-57 Throttle Lever Pin Cotter D0-54 53 Valve Face Cap Retaining Screw G57T-634 5 Throttle Control Arm K6U-555 54 Throttle Valve Spring D0-75 6 Throttle Lever Spring Stop Pin D0-553 55 Throttle Valve Cap K6U-943 Cylinder Assembly 6 K6U-A505A 56 Valve Chest Cover K6U-546 7 Cylinder Head K6U-H505A 57 Valve Chest Cover Gasket K6U-98 7A Cylinder Sleeve K6U-L505A 58 Valve Chest Cover Cap Screw D0-506 8 Cylinder Gasket 6 K6U-507 59 Cover Cap Screw Lock Washer D0-3 9 Cylinder Cap Screw 4 G8-3 60 Valve Chest Cap Screw 4 K6U-548 0 Cylinder Cap Screw Washer 4 K6U-504 6 Valve Chest Cap Screw Lock Washer 4 D0-3 Piston Assembly 6 K6U-A53A 6 Motor Eyebolt KU-888 Piston Ring Set K6U-337-6 63 Motor Case Cap Screw 5-36 3 Oil Regulating Piston Ring Set K6U-338-6 64 Motor Case Cap Screw Lock Washer A-67 4 Piston Wrist Pin 6 K6U-54 65 Motor Case Gasket K6U-59 Crank Assembly K6U-A56 66 Base 5 Crank K6U-56 for K6U or K6UA K6U-564 6 Crank Pin Sleeve K6U-59 for K6UL or K6UAL K6UL-564 7 Crank Lock Pin KU-50 67 Motor Mounting Bracket K6U-50 8 Crank Lock Pin Nut D0-37 68 Drum Shaft Short Screw HU-867 9 Crank Lock Pin Cotter D03-330 69 Base Bolt 8 K6UL-775 30 Oil Splasher KU-540 70 Base Bolt Lock Washer 8 D0-69 3 Oil Splasher Long Rivet K6U-54 7 Base Bolt Nut 8 DU-56 Oil Splasher Short Rivet 4-7 7 Rope Drum 3 Connecting Rod 6 K6U-509 for K6U or K6UA K6U-34 33 Connecting Rod Ring 4 K6U-50 for K6UL or K6UAL K6UL-34 34 Connecting Rod Bushing K6U-5 73 Rope Drum Large Seal K6U-37 35 Crank Valve End Bearing KU-58 74 Rope Drum Small Seal 0-37A 36 Crank Splined End Bearing KU-895 75 Drum Bearing K6U-466 Valve Chest Assembly K6U-A545 75A Bearing Retainer 3-406 37 Valve Chest K6U-545 76 Planet Gear Shaft 3 K6U-787 38 Grease Fitting 3-88 77 Rope Set Screw K6U-38 39 Brake Inlet Plug D0-40 78 Planet Gear 3 K6U-K73 NOT ILLUSTRATED When ordering a Motor Assembly or Motor Case, the model of the winch must be specified on the order to assure that the name plate on the new Motor Case is stamped with the correct model symbol. To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of each part indicated by a bullet ( ) for every four tools in service.
K6U PARTS LIST Item No. Description of Part Unit Total Part Number Item No. Description of Part Unit Total Part Number 79 Planet Gear Bearing 6 K6U-788 Gear Case Cover Cap Screw 9 5-48 80 Planet Gear Spacer 6 K6U-743 3 Gear Case Cover Cap Screw Washer 9 D0-3 8 Planet Gear Retainer 3 K6U-36 4 Long Brake Band K6U-5 8 Drum Thrust Plate 3 K6U-469 5 Long Brake Lining K6U-55 83 Drum Shaft 6 Brake Lining Long Rivet 9 K6U-57 for K6U or K6UA K6U-459 7 Brake Lining Short Rivet 3 K6U-56 for K6UL or K6UAL K6UL-459 8 Short Brake Band K6U-5 84 Intermediate Gear K6U-K364 9 Short Brake Lining K6U-55 85 Intermediate Gear Bearing K6U-366 0 Brake Lining Short Rivet 7 K6U-56 85A Bearing Retainer 3-406 Brake Lining Long Rivet 9 K6U-57 86 Motor Shaft Brake Lever 3-75 for K6U or K6UA K6U-36 3 Brake Lever Bolt D0-3 for K6UL or K6UAL K6UL-36 4 Brake Lever Bolt Nut WF7-3 87 Motor Pinion Key EEG-768 Brake Lever Screw R0H-354 88 Motor Shaft Nut 5-65 5 Brake Lever Extension 3-65 89 Motor Shaft Nut Lock 5-66 6 Brake Adjusting Screw 3-79 90 Motor Shaft Bearing 5-55 7 Brake Adjusting Nut D0-34A 9 Motor Shaft Pinion 8 Brake Trunnion 5-59 for K6U or K6UL K6U-39 9 Brake Bracket Pin K6U-47 for K6UA or K6UAL K6UA-39 30 Bracket Pin Cotter D0-330 9 Motor Pinion Thrust Washer K6U-397 3 Brake Anchor Pin K6U-06 93 Drive Shaft K6U-358 3 Anchor Pin Cotter 4 D0-330 94 Drive Gear Key 3-70 33 Brake Support K6U-6A 95 Drive Shaft Nut 5-73 34 Brake Support Pin K6U-06 96 Drive Shaft Nut Lock 5-74 36 Brake Support Cotter D0-330 97 Drive Shaft Outer Bearing 5-63 Exhaust Muffler KU-674 98 Drive Shaft Inner Bearing 5-4 Winch Nameplate DU-30R 99 Drive Gear Nameplate Screw 4 R4K-30 for K6U or K6UL K6U-357 Caution Plate TA-47A for K6UA or K6UAL K6UA-357 Caution Plate Screw 4 R4K-30 00 Drive Gear Spacer K6U-356 Rope Direction Plate DU-3 0 Ring Gear K6U-78 0 Ring Gear Short Cap Screw 5-48 03 Ring Gear Long Cap Screw 5 00-457 04 Ring Gear Cap Screw Lock Washer 6 D0-3 05 Gear Case K6U-353 06 Gear Case Cover Dowel HU-67 07 Drum Shaft Long Set Screw K6U-868 08 Grease Plug SR-65 09 ¼ Pipe Plug E5UD-947 0 Gear Case Cover K6U-35 Grease Plug SR-65 Eccentric Shaft Lock Screw J3-83 Gear Cover Plug K6U-78 Gear Cover Plug Seal HU-730 Grease Fitting 3-88 NOT ILLUSTRATED When ordering a Motor Assembly or Motor Case, the model of the winch must be specified on the order to assure that the name plate on the new Motor Case is stamped with the correct model symbol. To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of each part indicated by a bullet ( ) for every four tools in service.
K6U PARTS LIST Item No. Description of Part Unit Total Part Number Item No. Description of Part Unit Total Part Number AUTO BAND BRAKE PARTS DISENGAGING CLUTCH PARTS Air Cylinder HUR-70 500 Drive Shaft K6U-C358 Air Cylinder Rod End Clevis HUR-79 50 Clutch Jaw Lock Plug HU-864 3 Reducer FP5004 50 Clutch Jaw Lock Sprint K4U-863 4 Brake Lever K6UR-78 503 Clutch Jaw Lock Ball K4U-863 5 Cylinder Compression Spring HUR-76 504 Drive Gear Washer Retainer K6U-36 6 Air Cylinder Pivot Pin ¾ Diameter 4094-0 505 Clutch Jaw K4U-568 7 Cotter Pin 4 AG76865 506 Drive Gear Washer K6U-363 8 Hex Head Cap Screw Plated FQ04086 507 Clutch Eccentric Shaft K6U-857 9 Lock Washer Plated FQ50 508 Eccentric Pin Lock Screw HU-860 0 Brake Cylinder Bracket K6UR-7 509 Clutch Eccentric Pin HU-859 Street El FP50035 50 Clutch Eccentric Roller HU-858 Stop Tube Cored 40757 5 Drive Gear 3 Air Cylinder Rod Pin 4094- for K6U, K6UL K6U-C357 4 Quick Exhaust Valve K6UR-733 for K6UA, K6UAL K6UA-C357 5 Dust Excluder Valve FH005 5 Gear Case Cover K6U-C35 6 Long Brake Band Assembly K6U-5 53 Grease Fitting 3-88 7 Brake Lever Pin K6U-49 54 Grease Plug SR-65 8 Brake Bracket Short Pin K6U-48 55 Eccentric Shaft Lock Screw J3-83 9 Cotter D0-330 56 Clutch Lever HU-565 0 Screw Jam Nut K6U-760 57 Latch Spring HU-567 Auto Brake Adjusting Screw K6U-758 58 Clutch Latch HU-566 Brake Bracket Pin K6U-47 59 Clutch Lever Pin HU-56 3 Short Brake Band Assembly K6U-5 3/8 Lock Washer D0-3 Muffler K6AB-674 Black 50# PSI Push-LOK Hose/ft. 6 80-4 Pushlock Fitting FP004 WARNING Yoke K6U-759 DISENGAGING CLUTCH PARTS Bleed Valve HU-64-4 Bushing FP5007 Cotter SS 4 FQ0007 It is emphatically recommended that Automatic Brake and Disengaging Clutch features not be used on any Winch used for hoisting or otherwise subjected to an overhauling load. If for any reason, the Disengaging Clutch is left operative in a Winch used under either of the above conditions, it is the responsibility of the user to make provision to prevent accidental operation of the Winch motor with the clutch disengaged. Operation of the motor with the clutch disengaged while holding a suspended load will allow the load to drop. NOT ILLUSTRATED When ordering a Motor Assembly or Motor Case, the model of the winch must be specified on the order to assure that the name plate on the new Motor Case is stamped with the correct model symbol. To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of each part indicated by a bullet ( ) for every four tools in service.
Item No. Description of Part Unit Total Part Number REMOTE CONTROL PARTS Remote Control Block Assembly for winches with Standard Brake KU-B685 for winches with Automatic Brake KU-B685 500 Remote Control Block KU-685 50 Control Arm Retainer KU-687 50 3/8 Lock Washer D0-3 503 Control Arm Restrainer Screw HU-865 504 Throttle Lever Pin HU-870 * Throttle Lever Pin Cotter D0-54 505 Control Block Throttle Lever Spring K6U-4 506 Control Block Throttle Control Arm KU-555A 507 Throttle Lever Spring Stop Pin D0-553 508 Control Block Throttle Lever HU-556 509 Throttle Lever Latch HU-869 50 Throttle Lever Set Screw HU-84 5 Latch Spring HU-567 5 Control Block Throttle Valve Cap KU-943 53 Control Block Throttle Valve Spring HU-94 54 Control Block Poppet Throttle Valve KU-940 55 Control Block Throttle Valve Ball D0-80 56 Control Block Reverse Valve for winches with Standard Brake KU-K744A for winches with Automatic Brake KU-K744A 57 Control Block Valve Chest Cover KU-546A 58 Control Block Valve Chest KU-876A 59 Bushing Key HU-538 50 Throttle Lever Spring Stop Pin D0-553 5 Control Block Reverse Valve Bushing KU-945S * Grease Fitting 3-88 * Brake Inlet Plug D0-40 Remote Control Valve Chest Assembly K6U-A686 5 Remote Control Valve Chest K6M-545 53 Rotary Valve Bushing K6U-55S 54 Bushing Key HU-538 55 Rotary Valve K6U-56 56 Rotary Valve Key K6U-57 57 Rotary Valve Key Screw 4E-638 58 Valve Key Screw Lock Washer 4U-58 59 Remote Control Valve Chest Cover K6M-546 530 Remote Control Valve Chest Cover Gasket K6M-98 K6U PARTS LIST NOT ILLUSTRATED When ordering a Motor Assembly or Motor Case, the model of the winch must be specified on the order to assure that the name plate on the new Motor Case is stamped with the correct model symbol. To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of each part indicated by a bullet ( ) for every four tools in service.
B A 4 NOTES:. REMOVE ALL BURRS AND BREAK SHARP EDGES AND CORNERS.. ALL WELDS: A) SHALL BE IN ACCORDANCE WITH ANSI/AWS D.-LATEST REVISION. B) SHALL BE CONTINUOUS UNLESS OTHERWISE NOTED. C) SHALL BE SEALED WHEREVER AN OPENING EXSITS AT THE END OF THE WELD. D) SHALL BE VISUALLY INSPECTED AND ACCEPTED PER SUBSECTION 6, PART C, PARA. 6.9. 3. EXPANDED METAL PANELS ARE WELDED TO OUTSIDE SURFACE. 3 REV DESCRIPTION DATE ECN# 0 INITIAL RELEASE /6/009 --- SEE NOTE 3 OPENING (65 ) 4 SEE NOTE 3 70 45 R / INSIDE 45 3 SEE NOTE 3 3 SEE NOTE 3 TYP /8 6 /4 3 3/4 5/8- UNC TYP 5 5/8 3 TYP 7 6 5 5/8 7 6 5 4 3 ITEM 406083-04 406083-03 406083-0 7 406083-0 8 FQ355 5/8- HEX NUT 36SS. 8 FQ55 5/8 REG LOCKWASHER 36SS.0 8 FQ0406 5/8 FLAT WASHER WIDE 36SS.0 EXPANDED METAL, / X #3 X -5/8 X 37-5/6 CS 58.0 EXPANDED METAL, / X #3 X -5/8 X -/ CS 0.0 Ø5/8 ROUND BAR, " LG ASTM A36.0 Ø5/8 ROUND BAR, 7-3/4" LG ASTM A36 6.3 DRAW NO. QTY. PART NO. DESCRIPTION EXPANDED DESCRIPTION WT(LBS) PARTS LIST 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 () ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; () 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. 7 EST. FINISHED WT. 98 ACTUAL WT. ORIGINAL JOB NO: LBS LBS 3rd ANGLE PROJECTION UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS STATED ANGLES: 0.5 DIMENSIONS: SURFACE FINISH: X.X ±0.06 ON ALL X.XX ±0.05 5 MACHINED X.XXX ±0.005 SURFACES FRACTION ±/6 SURFACE FEATURES: MACHINED PARTS ONLY T.I.R.005 PERPENDICULAR.05 FLATNESS 0.00 PARALLEL.05 4603 CHRISMAN HOUSTON, TX 77039 BREAK ALL SHARP EDGES TITLE: DRUM GUARD ", 30 THRU 45 DWN: W. CULBERTSON /6/009 WRTOA CKD: M. KLEIN /6/009 DWG NUMBER: ENG: M. WEHMEYER /6/009 B 406083 0 SIZE: REV: K6U/A- APVD: M. WEHMEYER /6/009 AG06083 SCALE: /8 SH: OF PT/NO: NEXT ASSEMBLY MODEL NO. 4 3 B A - - - - - - -
B A 4 NOTES:. REMOVE ALL BURRS AND BREAK SHARP EDGES AND CORNERS.. ALL WELDS: A) SHALL BE IN ACCORDANCE WITH ANSI/AWS D.-LATEST REVISION. B) SHALL BE CONTINUOUS UNLESS OTHERWISE NOTED. C) SHALL BE SEALED WHEREVER AN OPENING EXSITS AT THE END OF THE WELD. D) SHALL BE VISUALLY INSPECTED AND ACCEPTED PER SUBSECTION 6, PART C, PARA. 6.9. 3. EXPANDED METAL PANELS ARE WELDED TO OUTSIDE SURFACE. 3 REV DESCRIPTION DATE ECN# 0 INITIAL RELEASE /5/009 --- SEE NOTE 3 OPENING (65 ) 4 SEE NOTE 3 70 45 R / INSIDE 45 3 SEE NOTE 3 3 SEE NOTE 3 TYP /8 6 /4 3 3/4 5/8- UNC TYP 5 5/8 3 TYP 7 6 5 4 5/8 7 6 5 4 3 ITEM 406098-04 406098-03 406098-0 7 406098-0 8 FQ355 5/8- HEX NUT 36SS. 8 FQ55 5/8 REG LOCKWASHER 36SS.0 8 FQ0406 5/8 FLAT WASHER WIDE 36SS.0 EXPANDED METAL, / X #3 X 4 5/8 X 37-5/6 CS 87.0 EXPANDED METAL, / X #3 X 4 5/8 X -/ CS 38.0 Ø5/8 ROUND BAR, 4" LG ASTM A36. Ø5/8 ROUND BAR, 7-3/4" LG ASTM A36 6.3 DRAW NO. QTY. PART NO. DESCRIPTION EXPANDED DESCRIPTION WT(LBS) PARTS LIST 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 () ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; () 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. 7 EST. FINISHED WT. 5 ACTUAL WT. ORIGINAL JOB NO: LBS LBS 3rd ANGLE PROJECTION UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS STATED ANGLES: 0.5 DIMENSIONS: SURFACE FINISH: X.X ±0.06 ON ALL X.XX ±0.05 5 MACHINED X.XXX ±0.005 SURFACES FRACTION ±/6 SURFACE FEATURES: MACHINED PARTS ONLY T.I.R.005 PERPENDICULAR.05 FLATNESS 0.00 PARALLEL.05 4603 CHRISMAN HOUSTON, TX 77039 BREAK ALL SHARP EDGES TITLE: DRUM GUARD 4", 30 THRU 45 DWN: W. CULBERTSON /5/009 WRTOA CKD: M. KLEIN /5/009 DWG NUMBER: ENG: M. WEHMEYER /5/009 B 406098 0 SIZE: REV: K6U/A-4 APVD: M. WEHMEYER /5/009 AG06098 SCALE: /6 SH: OF PT/NO: NEXT ASSEMBLY MODEL NO. 4 3 B A - - - - - - -
A B 3 6 /4 3 3/4 45 4 4 SEE NOTE 3 5 5/8 5/8- UNC - A TYP R / INSIDE OPENING 80 3 TYP 3 7 5 6 7 3 TYP /8 SEE NOTE 3 NOTES:. REMOVE ALL BURRS AND BREAK SHARP EDGES AND CORNERS.. ALL WELDS: A) SHALL BE IN ACCORDANCE WITH ANSI/AWS D.-LATEST REVISION. B) SHALL BE CONTINUOUS UNLESS OTHERWISE NOTED. C) SHALL BE SEALED WHEREVER AN OPENING EXSITS AT THE END OF THE WELD. D) SHALL BE VISUALLY INSPECTED AND ACCEPTED PER SUBSECTION 6, PART C, PARA. 6.9. 3. EXPANDED METAL PANELS ARE WELDED TO OUTSIDE SURFACE. 4 5/8 4 SEE NOTE 3 406099-0 6 EXPANDED METAL, / X #3 X 5/8 X -/ Ø5/8 ROUND BAR, " LG Ø5/8 ROUND BAR, 7-3/4" LG - PARTS LIST DESCRIPTION EXPANDED METAL, / X #3 X 5/8 X 34-5/8 - PART NO. 5/8 FLAT WASHER WIDE 5/8 REG LOCKWASHER 5/8- HEX NUT ASTM A36 ASTM A36 CS CS 36SS 36SS 36SS DATE //00 /5/009 EXPANDED DESCRIPTION CHANGED OPENING ANGLE FROM:70 TO:80 FQ0406 FQ55 FQ355 INITIAL RELEASE 0 DESCRIPTION REV WT(LBS) 6.3.0 0.0 55.0.0.0. 087 NA ECN# LBS LBS ACTUAL WT. NEXT ASSEMBLY ORIGINAL JOB NO: 8.4 EST. FINISHED WT. MODEL NO. K6U/A- 3rd ANGLE PROJECTION PERPENDICULAR D.05 PARALLEL H.05 M. WEHMEYER APVD: M. WEHMEYER ENG: M. KLEIN CKD: W. CULBERTSON DWN: /5/009 /5/009 /5/009 /5/009 BREAK ALL SHARP EDGES 0.00 T.I.R V.005 FLATNESS SURFACE FEATURES: MACHINED PARTS ONLY UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS STATED B0.5 DIMENSIONS: ANGLES: SURFACE FINISH: ±0.06 X.X ON ALL ±0.05 X.XX 5 MACHINED ±0.005 X.XXX SURFACES ±/6 FRACTION PT/NO: SIZE: B TITLE: 406099 AG06099 DWG NUMBER: /6 SCALE: OF SH: REV: DRUM GUARD ", VERTICAL (0 ) AND HORIZONTAL (90 ) WRTOA 4603 CHRISMAN HOUSTON, TX 77039 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 () ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; () 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. DRAW NO. QTY. 406099-03 406099-0 406099-04 4 8 5 3 8 8 - SEE NOTE 3 7 3 6 ITEM A B
A B 4 6 /4 3 3/4 45 4 4 SEE NOTE 3 5 5/8 5/8- UNC TYP R / INSIDE OPENING 80 7 5 6 7 TYP /8 SEE NOTE 3 3 TYP 3 NOTES:. REMOVE ALL BURRS AND BREAK SHARP EDGES AND CORNERS.. ALL WELDS: A) SHALL BE IN ACCORDANCE WITH ANSI/AWS D.-LATEST REVISION. B) SHALL BE CONTINUOUS UNLESS OTHERWISE NOTED. C) SHALL BE SEALED WHEREVER AN OPENING EXSITS AT THE END OF THE WELD. D) SHALL BE VISUALLY INSPECTED AND ACCEPTED PER SUBSECTION 6, PART C, PARA. 6.9. 3. EXPANDED METAL PANELS ARE WELDED TO OUTSIDE SURFACE. 3 3 4 5/8 4 SEE NOTE 3 3 6 Ø5/8 ROUND BAR, 7-3/4" LG - PARTS LIST DESCRIPTION Ø5/8 ROUND BAR, 4" LG PART NO. EXPANDED METAL, / X #3 X 4 5/8 X -/ - EXPANDED METAL, / X #3 X 4 5/8 X 34-5/8-5/8 FLAT WASHER WIDE 5/8 REG LOCKWASHER 5/8- HEX NUT ASTM A36 ASTM A36 CS CS 36SS 36SS 36SS DATE //00 /5/00 EXPANDED DESCRIPTION CHANGED OPENING ANGLE FROM:70 TO:80 FQ0406 FQ55 FQ355 INITIAL RELEASE 0 DESCRIPTION REV WT(LBS) 6.3. 38.0 8.0.0.0. 087 NA ECN# NEXT ASSEMBLY ORIGINAL JOB NO: ACTUAL WT. 46.3 EST. FINISHED WT. LBS LBS MODEL NO. K6U/A-4 3rd ANGLE PROJECTION PERPENDICULAR D.05 PARALLEL H.05 M. WEHMEYER APVD: M. WEHMEYER ENG: M. KLEIN CKD: W. CULBERTSON DWN: /5/009 /5/009 /5/009 /5/009 BREAK ALL SHARP EDGES 0.00 T.I.R V.005 FLATNESS SURFACE FEATURES: MACHINED PARTS ONLY UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS STATED B0.5 DIMENSIONS: ANGLES: SURFACE FINISH: ±0.06 X.X ON ALL ±0.05 X.XX 5 MACHINED ±0.005 X.XXX SURFACES ±/6 FRACTION PT/NO: SIZE: B TITLE: 40600 AG0600 DWG NUMBER: /6 SCALE: OF SH: REV: DRUM GUARD 4", VERTICAL (0 ) AND HORIZONTAL (90 ) WRTOA 4603 CHRISMAN HOUSTON, TX 77039 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 () ONLY USE THE DRAWING OR THE DESIGN AND DATA SHOWN FOR THE PURPOSE INTENDED BY RAM ITC; () 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. DRAW NO. QTY. 40600-0 ITEM 40600-03 40600-0 40600-04 4 8 5 3 8 8-7 6 SEE NOTE 3 A B
RAM P/N LB80040R FILTER Specifications Pipe Size /4 Net Bowl Capacity oz. (cm 3 ) 6. (80) Weight lbs. (kgf) 6.94 (3.5) Proof Pressure psig (Mpa) 0 (.5) Max. Operating Pressure psig (Mpa) 50 (.0) Operating Temperature Range 3 ~ 40 F (-5 ~ 60 C) Filtration 40 µm Flow Characteristics