INS

STRUCT
TIONS, PARTS
P AND
A MA
AINTENA
ANCE M
MANUAL
L

AIR
A R WIN
W NCCH
AW
AW2.9BK
K66-122AX
X1

WA
ARNING
G!

Review
w “WINC
CH OPER
RATING PRACTIICES” prrior to usee.
Always operate,
o inspeect and main
ntain this wiinch in accoordance with American N National Stanndards
Institute Safety
S Code (AANSI B30.7)) and any otheer applicable safety codes and regulatioons.

This wincch is only a co

omponent of the
t lifting sysstem, which m
must be designned by qualiffied personnell.

14603 CHRIISMAN RD, HO

OUSTON, TEXAS 7
77039 P
Phone: (281)999
9‐8665 F
FAX: 281‐999‐8666 or (888)726
6‐5438
 TABLE OF CONTENTS

Warning Tags
Safety Guidelines
Winch Operating Practices

1.0 General Information

1.1 User Responsibility and Safety Precaution

1.2 Introduction

1.2.1 Purpose
1.2.2 Model Number, Serial Number, and Options
1.2.3 Warranty

1.3 Equipment Description

1.3.1 Capabilities and Limitations

1.3.2 Specification and Descriptive Data

2.0 Functional Description

2.1 Major Assembles

2.1.1 Drive Assembles

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

Page 1 of 2

3.4 Installation Checkout Page 1 of 2

 3.4.1 Phase-1 Installation Inspection
3.4.2 Phase-2 Start Up and Preliminary Test

3.5 Cable Installation

3.5.1 Cable Termination on Drum

3.5.2 Spooling Cable onto Drum

4.0 Operating Instructions

4.1 Operator Start Up
4.2 Shutdown/Turn Off

5.0 Maintenance Procedure

5.1 Introduction
5.2 Maintenance Plan
5.2.1 Lubrication Schedule
5.2.2 Cleaning
5.2.3 Cable and Hoses

6.0 Component Removal/Replacement

Appendices
Winch Design & Performance Characteristics
RAM Winch & Hoist Parts Information
General Arrangement Installation Drawing
General Assembly Illustration
General Assembly Parts List
K6U Air Motor Parts Illustration
K6U Air Motor Parts List
ᴓ33 ½” Auto-Brake Assembly Illustration & Parts List
Air Schematic Illustration & Parts List
Gearbox Assembly-Disassembly Manual

Page 2 of 2
 APPENDICES

Winch Design & Performance Characteristics

RAM Winch & Hoist Parts Information
General Arrangement Installation Drawing
General Assembly Illustration
General Assembly Parts List
K6U Air Motor Parts Illustration
K6U Air Motor Parts List
ᴓ33 ½” Auto-Brake Assembly Illustration & Parts List
Air Schematic Illustration & Parts List
Gearbox Assembly-Disassembly Manual
 Performance Chart
Winch Model: AW2.9BK6-12AX1
Drum Diam. (in.) 20
Drum Length (in.) 12
Flange Diam. (in.) 34.6
Wire Rope (in.) 1

Storage Flange Running

Pitch Diam. Total Line Speed Stall Line
Layer Per Layer Clearance Line Pull
(in.) Storage (ft.) (ft/min) Pull (lbs.)
(ft.) (in.) (lbs.)
1 21.00 63 63 6.3 28,427 25.0 40,868
2 22.73 68 132 5.4 26,261 27.1 37,754
3 24.46 74 205 4.6 24,402 29.1 35,081
4 26.20 79 284 3.7 22,788 31.2 32,761
5 27.93 84 368 2.8 21,375 33.2 30,730
6 29.66 89 458 2.0 20,127 35.3 28,935
7 31.39 95 552 1.1 19,016 37.4 27,339
8 33.12 100 652 0.2 18,022 39.4 25,909
9 34.86 105 757 -0.6 17,127 41.5 24,622
10 36.59 110 867 -1.5 16,316 43.5 23,456
11 38.32 115 982 -2.4 15,578 45.6 22,396
12 40.05 121 1103 -3.2 14,905 47.7 21,427
13 41.78 126 1229 -4.1 14,287 49.7 20,539
14 43.52 131 1360 -5.0 13,718 51.8 19,722
15 45.25 136 1496 -5.8 13,193 53.8 18,967
16 46.98 141 1637 -6.7 12,707 55.9 18,267
17 48.71 147 1784 -7.6 12,255 58.0 17,618
18 50.44 152 1936 -8.4 11,834 60.0 17,013
19 52.18 157 2093 -9.3 11,441 62.1 16,448
20 53.91 162 2255 -10.2 11,074 64.2 15,920
21 55.64 168 2423 -11.0 10,729 66.2 15,424
22 57.37 173 2596 -11.9 10,405 68.3 14,959
23 59.11 178 2773 -12.8 10,100 70.3 14,520
24 60.84 183 2957 -13.6 9,813 72.4 14,107
25 62.57 188 3145 -14.5 9,541 74.5 13,716
26 64.30 194 3339 -15.4 9,284 76.5 13,347
27 66.03 199 3537 -16.2 9,040 78.6 12,997
28 67.77 204 3741 -17.1 8,809 80.6 12,665
29 69.50 209 3951 -17.9 8,590 82.7 12,349
30 71.23 214 4165 -18.8 8,381 84.8 12,049
31 72.96 220 4385 -19.7 8,182 86.8 11,763
32 74.69 225 4610 -20.5 7,992 88.9 11,490
33 76.43 230 4840 -21.4 7,811 90.9 11,229
34 78.16 235 5075 -22.3 7,638 93.0 10,981
35 79.89 241 5316 -23.1 7,472 95.1 10,743

Notes:
1. The rope storage capacity meets ANSI B30.7 and ABS requirements of 1/2in.
of drum flange clearance. The unshaded areas also meet DNV and European
standards requiring 2.5 rope diameters of flange clearance.
2. Performance is based on 90 psi of air pressure at the motor inlet
 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.

 K6U MOTOR P/N #I506501
Parts List

No. Part Number Qty. Description No. Part Number Qty. (each) Description
(each)
K6U-A501 1 Motor Assembly 32 K6U-509 6 Connecting Rod
1 K6U-501 1 Motor Case 33 K6U-510 4 Connecting Rod Ring
2 D02-402 2 Drain Plug 34 K6U-511 2 Connecting Rod Bushing
3 D02-303A 1 Vent Cap 35 KU-518 1 Crank Valve End Bearing
4 D02-893 1 Vent Cap Cotter 36 KU-895 1 Crank Splined End Bearing
5 D02-891 1 Vent Cap Chain K6U-A545 1 Valve Chest Assembly
6 D02-421 1 S-Hook 37 K6U-545 1 Valve Chest
7 D02-889 1 Vent Cap Screen 38 23-188 2 Grease Fitting
8 6CND-233-1/2 1 Vent Cap Screen Retainer 39 D02-402 2 Brake Inlet Plug
9 HU-556 1 Throttle Lever 40 K6U-525S 1 Rotary Valve Bushing
10 HU-869 1 Throttle Lever Latch 41 HU-538 2 Bushing Key
11 HU-567 1 Latch Spring 42 K6U-945S 1 Reverse Valve Bushing
12 HU-842 1 Throttle lever Set Screw 43 D02-553 1 Throttle Lever Spring Stop Pin
13 K6U-412 1 Throttle Lever Spring 44 K6U-526 1 Rotary Valve
14 HU-870 1 Throttle Lever Pin 45 K6U-527 1 Rotary Valve Key
* D02-524 2 Throttle Lever Pin Cotter (3/32" x 3/4") 46 4E-638 2 Rotary Valve Key Screw
15 K6U-555 1 Throttle Control Arm 47 4U-58 2 Valve Key Screw Lock Washer
16 D02-553 1 Throttle Lever Spring Stop Pin 48 K6U-K744A 1 Reverse Valve Assembly
K6U-A505A 6 Cylinder Assembly * R18-311 1 Reverse Valve O-ring
17 K6U-H505A 1 Cylinder Head 49 K6U-941 1 Throttle Valve Ball
17A K6U-L505A 1 Cylinder Sleeve 50 K6U-940 1 Throttle Valve
18 K6U-507 6 Cylinder Gasket 51 K6U-259 1 Throttle Valve Face
19 G8-113 24 Cylinder Cap Screw 51A K6U-280 1 Throttle Valve Face Spacer
20 K6U-504 24 Cylinder Cap Screw Washer 52 K6U-257 1 Throttle Valve Face Cap
21 K6U-A513A 6 Piston Assembly 53 G57T-634 1 Valve Face Cap Retaining Screw
22 K6U-337-6 1 Piston Ring Set 54 D10-275 1 Throttle Valve Spring
23 K6U-338-6 1 Oil Regulating Piston Ring Set 55 K6U-943 1 Throttle Valve Cap
24 K6U-514 1 Piston Wrist Pin 56 K6U-546 1 Valve Chest Cover
K6U-A516 1 Crank Assembly 57 K6U-928 1 Valve Chest Cover Gasket
25 K6U-516 1 Crank 58 D02-506 2 Valve Chest Cover Cap Screw
26 K6U-519 1 Crank Pin Sleeve 59 D02-321 2 Cover Cap Screw Lock Washer
27 KU-520 1 Crank Lock Pin 60 K6U-548 4 Valve Chest Cap Screw
28 D02-317 1 Crank Lock Pin Nut 61 D10-322 4 Valve Chest Cap Screw Lock Washer
29 D02-330 1 Crank Lock Pin Cotter (1/8" x 1 1/4") 62 KU-888 1 Motor Eyebolt
30 KU-540 1 Oil Splasher 63 215-36 12 Motor Case Cap Screw
31 K6U-541 2 Oil Splasher Long Rivet 64 A-67 12 Motor Case Cap Screw Lock Washer
* 241-712 2 Oil Splasher Short Rivet 65 K6U-592 1 Motor Case Gasket
* Not Illustrated
Component Data Sheets
RAM P/N LB80045R
LUBRICATOR

Specifications

Proof Pressure psig (Mpa) 220 (1.5)

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

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

Recommended Lubricant Turbine Oil #1 (ISO VG32)

Pipe Size 1 ½” NPT

Oil Capacity (cm3) 500

Flow Rate /n/min 12500

RAM P/N LB80040R
FILTER

Specifications
Pipe Size (NPT) 111/4
1/2

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

Weight lbs. (kgf) 6.94 (3.15)

Proof Pressure psig (Mpa) 220 (1.5)

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

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

Filtration 40 Pm

Flow Characteristics
RAM P/N AG70252
RAM P/N AG03318
ACCESSORIES
®

SHUTTLE VALVES
a range of Shuttle Valves in different sizes, made from Brass or 316 Stainless Steel

General Description Functional 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 dis-
charge a pressure line or chamber from two - or more -
sources. A typical schematic is shown below:
Shuttle Valves have a free moving shuttle that blocks one of two
inlet ports while the other inlet port is connected to the (com-
mon) 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.

1 2 3 Pressures
Pressure range– Pneumatic: 5 to 200 psi (0.35 to 14 bar)
Materials Hydraulic: 5 to 500 psi (0.35 to 35 bar)
Type: Brass Stainless Steel
Body: Brass 316 Stainless Steel† Symbol OUT
Shuttle: Nylon(Zytel) 316 Stainless Steel† IN IN
Seals: NBR (Nitrile) FKM (Fluorocarbon)
Screws: Plated Steel 316 Stainless Steel†
Mounting
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-2 2.0 (51) 1.5 (38) 1.0 (25) 0.8 (12) 0.57 (0.26)
1/4 NPT SV-3 SV-3-316 2.0 (51) 1.5 (38) 1.0 (25) 0.8 (12) 0.5 (7) 0.57 (0.26) 0.33 (0.15)
3/8 NPT SV-4 2.5 (64) 1.9 (48) 1.3 (32) 1.6 (23) 1.10 (0.50)
1/2 NPT SV-5 2.5 (64) 1.9 (48) 1.3 (32) 2.1 (30) 1.10 (0.50)
3/4 NPT SV-6 3.5 (89) 2.8 (70) 1.5 (38) 6.5 (84) 2.16 (0.98)

* For Subplate Mounting Shuttle Valves Consult Factory

†conforms to NACE standard MR-01-75 ®

4
Model AW2.9BK6-12AX1G
RAM Winch & Hoist 03/2014