Instructions, Parts and Maintenance Manual

INVADER
AVENGER
MODEL K5UR100ML
UTILITY AND MANLIFTER
AIR WINCH

Warning!
Review “WINCH OPERATING PRACTICES” Prior to use.
Always operate, inspect and maintain this winch in accordance with American National Standards Institute
Safety Code (ANSI B30.7) and any other applicable safety codes and regulations.

This winch is only a component of the lifting system, which must be designed by qualified personnel.

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

4.0 Operating Instructions

4.1 Operator Start Up

4.2 Shutdown

5.0 Preventive Maintenance

5.1 Introduction

5.2 Maintenance Plan

5.2.1 Lubrication Schedule
5.2.2 Cleaning
5.2.3 Cable and Hoses
5.2.4 In Field Load Brake Adjustment Procedure

6.0 Component Removal/Replacement

Appendices
Personnel Rating Performance Characteristics
Utility Rating Performance Characteristics
RAM Winch & Hoist Parts Information
Avenger 100 General Arrangement Drawing
Avenger 100 Drum Guard Drawing
Avenger 100 Exploded View Figures 1 through 5
Avenger 100 Winch Assembly Bill of Material
Avenger 100 Manual Brake Bill of Material
Avenger 100 Auto Brake Bill of Material
Avenger 100 Manual & Auto Brake Bill of Material
Avenger 100 Recommended Spares
K5U Air Motor Parts Listing
K5U Air Motor Assembly Illustration
DoubleWheel
Power Reduction Wheel
Service DriveModel
Manual Service
9 Manual
Component Data Sheets
1.0 General Information

1.1 User Responsibility and Safety Precautions

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

This equipment will perform in conformity with the description thereof, contained in this
manual, its accompanying labels and/or inserts when it is installed, operated, maintained and
repaired according to the instructions provided. This equipment must be checked periodically.

Deficient equipment should not be used. Parts that are broken, missing, plainly worn, distorted
or contaminated should be replaced immediately. Should such repair or replacement become
necessary, we recommend that a telephone or written request for service be made to RAM
Winch & Hoist.

This equipment or any of its parts should not be altered without prior written approval of RAM
Winch & Hoist. The user of this equipment shall have the sole responsibility for any
malfunction that results from improper use, faulty maintenance, damage, improper repairs or
alterations made by anyone other than RAM Winch & Hoist.

1.2 Introduction

1.2.1 Purpose

The purpose of this manual is to provide operating instructions and maintenance procedures for
your RAM Winch & Hoist Air Winch.

1.2.2 Model Number, Serial Number and Options

This manual covers the winch built by RAM Winch & Hoist for your particular unit. The model
and serial numbers are listed on the nameplate attached to the unit.

1.2.3 Warranty

See standard warranty certificate.

1.3 Equipment Description

1.3.1 Capabilities and Limitations

The winch is an air, planetary driven cable-handling unit with manual release and auto release
band brakes, designed for use in the marine or industrial environment.
See Performance Chart
above
 AVENGER K5UR100ML PERSONNEL RATING
PERFORMANCE CHARACTERISTICS -- DUAL BRAKE UNIT
NOTE: WIRE ROPE MINIMUM BREAKING STRENGTH MUST BE 10 TIMES THE LINE PULL RATING IN
ORDER TO MEET PERSONNEL RATING REQUIREMENTS

K5UR100ML-8

K5UR100ML-14

K5UR100ML-20

K5UR100ML-26

K5UR100ML-32
 BILL OF MATERIALS
“DAUNTLESS” (K5UR50), “DAUNTLESS D” (K5UR50D),
“AVENGER” (K5UR90), “AVENGER” (K5UR100), “INVADER” (K5UR120)

WINCH ASSEMBLY CONTINUED

ITEM QTY PART NUMBER DESCRIPTION WT (LBS)

K5UR-032-24 20” or 24” Between Flanges 33
K5UR-032-30 26” or 30” Between Flanges 39
K5UR-032-36 32” or 36” Between Flanges 44
6 6 HUR-010 Tie Bar Flange Bolt 3
7 6 HUR-018 Tie Bar O-Ring, Small 0
8 6 HUR-222 Tie Bar O-Ring, Large 0
9 1 GEARBOX ASSEMBLY
K5UR50-A353 For Dauntless 105
K5UR50D-A353 For Dauntless D 105
K5UR90-A353 For Avenger 90 169
K5UR100-A353 For Avenger 100 169
K5UR120-A353 For Invader 169
10 10 DRUM/GEARBOX HEX BOLT
K5UR50-354 For Dauntless & Dauntless D 2
K5UR90-354 For Avenger & Invader 2
11 10 LOCKWASHER
K5UR50-TAB For Dauntless & Dauntless D 0
K5UR90-TAB For Avenger & Invader 0
12 8 FRAME/GEARBOX HEX BOLT
K5UR50-355 For Dauntless & Dauntless D 2
K5UR90-355 For Avenger & Invader 2
13 8 AG78056 WASHER 0
14 1 INTERFACE SHAFT
K5UR-506 For Dauntless/Dauntless D & Avenger 3.5
K5UR120-506 For Invader 5
15 2 K5UR-016 Shaft Oil Seal 1
16 1 KD5-A501 Air Motor W/Controls 360
17 10 KX-36 Frame/Motor Hex Bolt 2
18 10 A-67 Lockwasher 0
19 1 KU-895 Bearing, Crank Motor End 1
20 1 KK5UM-545 Valve Chest
21 1 KU-546A Valve Chest Cover
22 4 KU-548 Hex Head Capscrew 1
23 4 D10-322 Lockwasher 1
24 1 K5UR-466 Bearing 4
25 1 K5UR-508 Bearing End Cover 3.5
26 4 D02-354 Hex Head Capscrew 1
27 4 D02-321 Lockwasher 0
28 2 HUR-165 Oil Hex Plug 0
29 1 HUR-381 Rope Locking Wedge 1
30 1 DRUM/GEARBOX GASKET
HUR-594 For Dauntless & Dauntless D 0
HUR-594 For Avenger & Invader 0
31 1 FRAME/GEARBOX GASKET
HUR-593 For Dauntless & Dauntless D 0
K5UR-593 For Avenger & Invader 0
32 1 HUR-592 Frame/Motor Gasket 0
33 1 HUR-595 Bearing End Cover Gasket 0

See Fig. 1
Brake Mount Assembly
 RECOMMENDED SPARES
“DAUNTLESS” (K5UR50), “DAUNTLESS D” (K5UR50D),
“AVENGER” (K5UR90), “AVENGER” (K5UR100), “INVADER” (K5UR120)

QTY PART NO DESCRIPTION

1 HU-942 Poppet Throttle Valve Spring
1 KU-527 Large Valve Drive Pin
2 HU-527 Small Valve Drive Pin
1 HU-556 Throttle Lever
1 HU-567 Throttle Lever Latch Spring
1 KU-519 Crank Pin Sleeve
1 KU-518 Crank Valve End Bearing
1 KU-895 Crank Pin End Bearing
1 KU-337-5 Piston Ring Set
1 KU-338-5 Oil Regulating Ring Set
5 K5W-507
KU-507 Cylinder Gasket
1 K5M-592 Motor Case Gasket
1 K5UR-466 Drum Bearing
1 K5UR-508 End Cover Bearing
2 HUR-162 Clevis Pin
1 HUR-720 Air Cylinder
1 HUR-726 Compressor Spring
1 HUR-715 Brake Handle
1 KU-940 Poppet Throttle Valve
1 KU-943 Poppet Throttle Valve Cap
1 HU-870 Throttle Lever Pin
1 K6U-412 Throttle Lever Spring

Recommended Spares for two (2) Year Foreign Operation

FOB: Houston, Texas
Terms of Payment: Net 30 Days
PD5-H505A

K5W-507
KD5-A501 (Model No. AG78301)

402790-1M
 RAMP/N
RAM P/NAH04414R
AH04417
Double Reduction Wheel Drive
SERVICE MANUAL
 RAM
RAMP/N
Power Wheel® Service AH04414R
P/N AH04417
Manual
Double
Model 9 Double Reduction Wheel Drive
Reduction
Wheel Drives
Parts Illustration
AUBURN, INDIANA 46706-3499
U.S.A.

PHONE: (219) 925-3200

FAX: (219) 925-4725

3
1

2
4
5
6
7

8
9

10
11
12 13
14

18
15

17
19

20 16

25
21
22
23 27
24 26

32
33

34

28
31
29 30
OPTIONAL
 DISASSEMBLYOF
DISASSEMBLY OFPOWER
WHEELWHEEL
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 (30) if necessary.

STEP 4
Remove twenty-four bolts (26) and flat washers (27) and the large cover (25) from the unit. The thrust
washer (22) and the disengage plunger (23) usually remain attached to the large cover (25) when it is
removed. Remove thrust washer (22), disengage plunger (23) and “O” ring (24) from the large cover
(25).

STEP 5
Remove primary sun gear (21) from end of input shaft (2).

STEP 6
Remove the primary carrier assembly (20).

STEP 7
Remove the secondary carrier assembly (19). It may be necessary to remove the ring gear (18) first, if
difficulty is encountered removing the carrier.

STEP 8
Remove the input shaft (2) from spindle (3). Remove the retaining rings (15), washer (16), and
disengage spring (17) from input shaft (2) only if replacement is required.

STEP 9
If not previously removed (see step 7) remove ring gear (18) from hub (9). It may be necessary to strike
ring gear (18) with a rubber mallet to loosen from hub (9).

STEP 10
One tab of lock washer (13) will be engaged in the slot of bearing nut (14); bend back to release.
Remove the bearing nut (14), lock washer (13) and thrust washer (12). Note: A special locknut wrench,
593RR, required for the removal of the bearing locknut. Contact RAM Winch & Hoist for procurement
of wrench and other service tools.

STEP 11
Bolt spindle drive tool, 598FF, to hub (9). Drive spindle (3) from hub (9) by turning bolt in center of
spindle drive tool. Care should be taken to avoid damaging splines and threads on spindle. Note:
Bearing cone (11) has been designed with a press fit with respect to spindle (3). Considerable force will
be required to remove cone from spindle.

STEP 12
Remove the boot seal (4) and oil seal (5) and bearing cones (6 & 11) from hub (9). Inspect bearing
cups (7 & 10) in position and remove only if replacement is required.
 RAM
RAMP/N
Power Wheel® Service AH04414R
P/N AH04417
Manual
Double
Model 9 Double Reduction Wheel Drive
Reduction
Wheel Drives
Parts Illustration
AUBURN, INDIANA 46706-3499
U.S.A.

PHONE: (219) 925-3200

FAX: (219) 925-4725

3
1

2
4
5
6
7

8
9

10
11
12 13
14

18
15

17
19

20 16

25
21
22
23 27
24 26

32
33

34

28
31
29 30
OPTIONAL
 ASSEMBLYOF
ASSEMBLY OFPOWER
WHEELWHEEL
DRIVE
Refer to Parts Illustration
STEP 1
Press new bearing cups (7 & 10) in each side of the hub (9). It is recommended that bearing cups (7 &
10) and cones (6 & 12) be replaced in sets.

STEP 2
Assemble bearing cone (6) into cup (7) at seal end of hub (9) and press a new seal (5) into hub (9).
Install boot seal (4) on hub (9) if unit is so equipped.

STEP 3
Position spindle (3) upright on bench. Lubricate lips of seal (4) and (5) and lower hub (9) onto spindle
(3). Hub (9) should be centered as it is lowered over spindle (3) to prevent seal damage.

STEP 4
Assemble bearing cone (11) over spindle (3). Press bearing cone (11) over spindle bearing journal
using press and cylindrical bearing cone driver 598F. Pressure bearing cone (11) down until rollers just
touch cup (10). Take care to avoid pressuring cone (11) too far. Note: If a press is not available, place
tool 598F over splined end of spindle (3) on the edge of bearing cone (11) and drive into place with
hammer or mallet. If this method is used, care must be taken to avoid damage to bearing cone and
spindle.

STEP 5
Install thrust washer (12) and bearing nut (14). DO NOT install lock washer (13) at this time.

STEP 6
Place spindle drive tool, 598F, over spindle (3) and bolt or pin to hub (9).

STEP 7
Check initial rolling torque by installing a lb.-in. torque wrench (arm or dial type) on center nut of spindle
drive tool and turning hub (9) slowly and steadily with the torque wrench. Note mean torque. An initial
bearing torque of greater than 52-lb. –in. with boot seal installed or 48 lb. –in. without boot seal means
that the cone (11) was pressed on too tightly in step 4. In this case, back off bearing cone (11) by
pressing spindle (3) out of cone (11) until initial preload is relieved. See step 11 of disassembly
procedure.

STEP 8
Torque bearing nut (14) with bearing nut wrench 593RR until a bearing rolling torque of 44 – 52 lb. –
in., with a boot seal installed, or 40 – 48 lb. –in., without a boot seal, is reached. This may require
several trials of pressing the cone (11) by torquing the nut (14) and then checking the rolling torque.
Rotate hub (9) by hand as nut is being tightened in order to seat bearings. Note: Up to 250 lb. –ft. of
torque may have to be applied to bearing nut (14) in order to press cone (11) into position.

STEP 9
Remove bearing nut (14) and install lock washer (13). Replace bearing nut (14).

STEP 10
Re-torque bearing nut (14) to 65-75lb. – ft. (88 – 100 Nm).
 RAM
RAMP/N
Power Wheel® Service AH04414R
P/N AH04417
Manual
Double
Model 9 Double Reduction Wheel Drive
Reduction
Wheel Drives
Parts Illustration
AUBURN, INDIANA 46706-3499
U.S.A.

PHONE: (219) 925-3200

FAX: (219) 925-4725

3
1

2
4
5
6
7

8
9

10
11
12 13
14

18
15

17
19

20 16

25
21
22
23 27
24 26

32
33

34

28
31
29 30
OPTIONAL
STEP 11
Secure bearing nut (14) by bending a lock washer (13) tab into one of four bearing nut slots. If no tab
aligns with a slot, the nut may be tightened until one of the slots aligns with a lock washer tab.

STEP 12
Assemble a washer (16), spring (17), a second washer (16), and a retaining ring (15) in the middle
grooves of input shaft (2). Install a second retaining ring (15) in groove near small end of input shaft (2).

STEP 13
Assemble the splined end of the input shaft (2) down into spindle (3).

STEP 14
Assemble the secondary carrier assembly (19) to spindle (3) at splines.

STEP 15
Clean mating surfaces and apply a bead of silicone sealant to face of hub (9) that mates with ring gear
(18). See instructions on sealant package. Assemble ring gear (18) to hub (9) being careful to align bolt
holes.

STEP 16
Assemble the primary carrier assembly (20) into the ring gear (18). It will be necessary to rotate carrier
to align secondary sun gear {part of primary carrier assembly (20)} with planet gear teeth in secondary
carrier assembly (19). Assemble primary sun gear (21) over input shaft (2). Rotate primary sun gear
(21) to align input shaft (2) to gear splines and gear teeth in primary carrier assembly (20).

STEP 17
Lubricate “O” ring (24) and assemble in groove inside cover hole, push disengage plunger (23) into
cover (25) with pointed end facing inside of unit.

STEP 18
Assemble the thrust washer (22) with tangs engaged with cover (25). NOTE: A small amount of grease
applied to the back side of thrust washer (22) will hold washer in place. Apply a bead of silicone sealant
to end of face of ring gear (18). Assemble cover (25) aligning holes of cover and ring gear. Assemble
the twentyfour 3/8-16 x 6-1/2 inch grade 8 bolts (26) and flat washers (27). Torque bolts to 45 - 50 lb.-ft.
(61 - 67 Nm).

STEP 19
Assemble the disengage cover (30) with dimpled center protruding out if wheel is to be used to drive
the vehicle. Assemble and torque the two 5/16-18 x 1/2 inch bolts (31). Torque bolts to 10 - 20 lb.-ft. (13
- 27 Nm).

STEP 20
Invert the Power Wheel assembly and assemble the coupling (1) with counter bore out to the input shaft (2)

STEP 21
After motor is assembled to drive or drive is sealed at spindle, fill with lubricant to proper level and replace all
plugs.

Note: When installing a hydraulic motor to the Power Wheel drive it is necessary to place an “O” ring or
gasket between the motor and the planetary drive. “O” ring sizes: SAE A 2-042, SAE B 2-155, SAE C
2-159.
 RAM P/N AH04417

CARRIER ASSEMBLIES

It is recommended that the primary and secondary carrier assemblies (18 & 19) be serviced entirely to
protect the integrity of the Power Wheel drive.

LUBRICATION RECOMMENDATIONS

IMPORTANT:
POWER WHEEL PLANETARY DRIVES ARE SHIPPED WITHOUT LUBRICANT AND MUST BE
FILLED TO THE PROPER LEVEL PRIOR TO START UP.

Observe lubrication recommendations given by the original equipment manufacturer. When specific
recommendations are not available, use mild extreme pressure lubricant API-GL-5, No. 80 or 90 when
filling the Power Wheel under normal temperature ranges between 0 - 120°F (-18 to 49°C). Power
Wheel is to be half full of oil when unit is mounted level and horizontal. Use drain and fill plugs located
in cover and ring gear. Oil is to be changed after first 50 hours of operation with subsequent changes
every 1000 hours or yearly, which ever comes first. If unit is to be operated vertically, if ambient
conditions are outside the specified range, or if the oil temperature exceeds 200°F (93°C) contact RAM
Winch & Hoist for oil and level recommendations.

STORAGE

A protective film is applied to the Power Wheel at the factory to prevent rust during shipment. Additional
protection may be required if the Power Wheel is to be stored for an extended period of time.

SEALING COMPOUND

Silastic RTV732 sealer and General Electric Silimate RTV No. 1473 or RTV No. 1503 are currently
recommended for sealing gasket surfaces. Sealant should be applied in continuous bead, which should
be centered on the surface to be sealed but should move to the inside of the hole at each bolt hole
location. For service requirements order RAM Winch & Hoist part number 604101.

SPECIFICATIONS

Maximum intermittent output torque ..........................................................130,000 lb. In. (14,690 Nm)

Maximum input speed ................................................................................5,000 RPM
Oil capacity……………………………………………………………………....57 oz (1,685 ml)
 RAM
RAM P/N
Power Wheel® Service P/N AH04414R
AH04417
Manual
Double
Model 9 Double Reduction Wheel Drive
Reduction
Wheel Drives
Parts Illustration
AUBURN, INDIANA 46706-3499
U.S.A.

PHONE: (219) 925-3200

FAX: (219) 925-4725

3
1

2
4
5
6
7

8
9

10
11
12 13
14

18
15

17
19

20 16

25
21
22
23 27
24 26

32
33

34

28
31
29 30
OPTIONAL
PARTS LISTING

Refer to Parts Illustration Drawing for Item Numbers

Item No. Used Item No.Used

No. Description in Ass’y. No. Description in Ass’y.
1 Coupling 1 18 Ring Gear 1
2 Input Shaft 1 19 Secondary Carrier Assembly 1
3 Spindle 1 20 Primary Carrier Assembly 1
4 Boot Seal 604403 1 21 Primary Sun Gear 1
5 Oil Seal 604409 1 22 Thrust Washer 1
6 Bearing Cone 14-00-133-007 1 23 Disengage Plunger 1
7 Bearing Cup 14-00-133-006 1 24 “O” Ring 614101 1
8 Wheel Bolt 8-10 25 Large Cover 1
9 Hub 1 26 Hex Head Bolt (Grade 8) 24
10 Bearing Cup 613314 1 27 Flat Washer 24
11 Bearing Cone 613315 1 28 Magnetic Plug 14-00-052-002 1
12 Thrust Washer 619320 1 29 Pipe Plug 1
13 Lock Washer 605003 1 30 Disengage Cover 14-02-039-005 1
14 Bearing Nut 2 31 Hex Head Bolt 618305 1
15 Retaining Ring 2 32 Quick Disconnect Gasket 1
16 Washer 1 33 Quick Disconnect Assembly 2
17 Disengage Spring 615604 1 34 Hex Head Bolt 2

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

Wheel
Model Drive Service
9 Power Kits
Wheel Service Kits

Part No. Description Included Items

593RR Bearing Locknut Tool Not Shown

598F Bearing Cone Driver Not Shown
598FF Spindle/Shaft Drive Tool Not Shown
Component Data Sheets
RAM P/N AG35139
Air Cylinder
 RAM P/N AG35139
Air Cylinder

A
RAM P/N LB80045R
1 1/2" LUBRICATOR
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
1 1/2" FILTER
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 23° ~ 140° F (-5° ~ 60° C)

Filtration 40 µm

Flow Characteristics
RAM P/N LB80050
REGULATOR
RAM P/N LB80050
REGULATOR

SPECIFICATIONS

Port Size 1½
Proof Pressure psig (Mpa) 220 (1.5)
Max. Operating Pressure psig (Mpa) 150 (1.0)
Temperature 23 ~ 140° (-5 ~ 60C
Pressure Regulating Range psig (Mpa) 7 ~ 120 (0.05 ~ 0.83)
Body AC2A-F
Bonnet ADC
Chamber AC2A-F
Valve Guide AC2A-F
Weight lbs (kgf) 5.51 (2.5)

FLOW CHARACTERISTICS PRESSURE CHARACTERISTICS

Conditions: Supply Pressure 100 psig Supply Pressure – 100 psig
Secondary Pressure – 30 psig (0.2 Mpa)
Flow – 0.7 SCFM (20l/min)
RAM P/N LB80050
REGULATOR

No. Name Material Part No.

5 Exhaust Valve Assembly --- 132586A

6 Main Valve Diaphragm Assembly --- 13275A
7 Valve Assembly --- 132752A
8 Regulating Spring SWPB 135053
9 Valve Spring SUS304 132713
11 Pilot Diaphragm --- 135019-1A

Dimensions

A B C D E F
6.30 9.53 3.50 5.51 4.45 0.39
(160) (242) (89) (140) (113) (10)
RAM P/N AG70252
K5UR100ML AIR WINCH
POWER WHEEL Service Manual
RAM
RAMWinch
Winch&&Hoist
Hoist 11/06