Instructions, Parts and Maintenance Manual

AIR WINCH

MODEL K6U

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.

NO

TE: D

RU

M W

IDTH

IS 8

INC

HE

S F

OR

UN

ITS

EQ

UIP

PE

D W

ITH

DU

AL

BR

AK

E A

ND

12

INC

HE

S F

OR

UN

IT E

QU

IPP

ED

WIT

H S

ING

LE B

RA

KE

K6U

PA

RT

S L

IST

∗ N

OT

ILLU

STR

ATE

D

⊗ W

hen

orde

ring

a M

otor

Ass

embl

y or

Mot

or C

ase,

the

mod

el o

f the

win

ch m

ust b

e sp

ecifi

ed o

n th

e or

der t

o as

sure

that

the

nam

e pl

ate

on th

e ne

w M

otor

Cas

e is

sta

mpe

d w

ith th

e

c

orre

ct m

odel

sym

bol.

• T

o ke

ep d

ownt

ime

to a

min

imum

, it i

s de

sira

ble

to h

ave

on h

and

certa

in re

pair

parts

. We

reco

mm

end

that

you

sto

ck o

ne (p

air o

r set

) of e

ach

part

indi

cate

d by

a b

ulle

t (•)

for e

very

fou

r too

ls in

ser

vice

.

Ite

m N

o.

Des

crip

tion

of P

art

Uni

t Tot

al

Part

Num

ber

Ite

m N

o.

Des

crip

tion

of P

art

Uni

t Tot

al

Part

Num

ber

⊗

M

otor

Ass

embl

y

K6U

-A50

1

40

R

otar

y V

alve

Bus

hing

K6U

-525

S

⊗

1 M

otor

Cas

e

K6U

-501

41

B

ushi

ng K

ey

2 H

U-5

38

2

D

rain

Plu

g 2

D02

-402

42

R

ever

se V

alve

Bus

hing

K6U

-945

S

3

Ven

t Cap

D02

-303

A

43

Thr

ottle

Lev

er S

prin

g S

top

Pin

D02

-553

4

Ven

t Cap

Cot

ter

D

02-8

93

44

R

otar

y V

alve

K6U

-526

5

Ven

t Cap

Cha

in

D

02-8

91

45

Rot

ary

Val

ve K

ey

K

6U-5

27

6

S

-Hoo

k

D02

-421

46

R

otar

y V

alve

Key

Scr

ew

2 4E

-638

7

Ven

t Cap

Scr

een

D

02-8

89

47

Val

ve K

ey S

crew

Loc

k W

ashe

r 2

4U-5

8

8

Ven

t Cap

Scr

een

Ret

aine

r

6CN

D-2

33-1

/2

48

R

ever

se V

alve

Ass

embl

y

K6U

-K74

4A

9

Thr

ottle

Lev

er

H

U-5

56

∗

Rev

erse

Val

ve O

-Rin

g

R18

-311

10

T

hrot

tle L

ever

Lat

ch

H

U-8

69

49

T

hrot

tle V

alve

Bal

l

K6U

-941

•

11

L

atch

Spr

ing

H

U-5

67

50

T

hrot

tle V

alve

K6U

-940

12

T

hrot

tle L

ever

Set

Scr

ew

H

U-8

42

51

Thr

ottle

Val

ve F

ace

K

6U-2

59

• 13

T

hrot

tle L

ever

Spr

ing

K

6U-4

12

51

A

T

hrot

tle V

alve

Fac

e S

pace

r

K6U

-280

14

Thr

ottle

Lev

er P

in

H

U-8

70

52

Thr

ottle

Val

ve F

ace

Cap

K6U

-257

∗ T

hrot

tle L

ever

Pin

Cot

ter

2 D

02-5

24

53

Val

ve F

ace

Cap

Ret

aini

ng S

crew

G57

T-63

4

15

Thr

ottle

Con

trol A

rm

K

6U-5

55

• 54

T

hrot

tle V

alve

Spr

ing

D

10-2

75

16

Thr

ottle

Lev

er S

prin

g S

top

Pin

D02

-553

55

Thr

ottle

Val

ve C

ap

K

6U-9

43

Cyl

inde

r Ass

embl

y 6

K6U

-A50

5A

56

V

alve

Che

st C

over

K6U

-546

17

C

ylin

der H

ead

K

6U-H

505A

•

57

Val

ve C

hest

Cov

er G

aske

t

K6U

-928

17A

Cyl

inde

r Sle

eve

K

6U-L

505A

58

Val

ve C

hest

Cov

er C

ap S

crew

2

D02

-506

•

18

Cyl

inde

r Gas

ket

6 K

6U-5

07

59

C

over

Cap

Scr

ew L

ock

Was

her

2 D

02-3

21

19

C

ylin

der C

ap S

crew

24

G

8-11

3

60

Val

ve C

hest

Cap

Scr

ew

4 K

6U-5

48

20

C

ylin

der C

ap S

crew

Was

her

24

K6U

-504

61

Val

ve C

hest

Cap

Scr

ew L

ock

Was

her

4 D

10-3

22

21

P

isto

n A

ssem

bly

6 K

6U-A

513A

62

Mot

or E

yebo

lt

KU

-888

•

22

P

isto

n R

ing

Set

K6U

-337

-6

63

M

otor

Cas

e C

ap S

crew

12

21

5-36

•

23

O

il R

egul

atin

g P

isto

n R

ing

Set

K6U

-338

-6

64

M

otor

Cas

e C

ap S

crew

Loc

k W

ashe

r 12

A

-67

24

P

isto

n W

rist P

in

6 K

6U-5

14

65

M

otor

Cas

e G

aske

t

K6U

-592

C

rank

Ass

embl

y

K6U

-A51

6 •

66

Bas

e

25

Cra

nk

K

6U-5

16

for

K6U

or K

6UA

K6U

-564

•

26

C

rank

Pin

Sle

eve

K

6U-5

19

for

K6U

L or

K6U

AL

K

6UL-

564

27

Cra

nk L

ock

Pin

KU

-520

67

Mot

or M

ount

ing

Bra

cket

K6U

-502

28

Cra

nk L

ock

Pin

Nut

D02

-317

68

Dru

m S

haft

Sho

rt S

crew

HU

-867

29

C

rank

Loc

k P

in C

otte

r

D03

-330

69

Bas

e B

olt

8 K

6UL-

775

30

Oil

Spl

ashe

r

KU

-540

70

Bas

e B

olt L

ock

Was

her

8 D

01-6

92

31

O

il S

plas

her L

ong

Riv

et

2 K

6U-5

41

71

B

ase

Bol

t Nut

8

DU

-562

∗

O

il S

plas

her S

hort

Riv

et

2 24

1-71

2

72

Rop

e D

rum

32

Con

nect

ing

Rod

6

K6U

-509

for K

6U o

r K6U

A

K

6U-3

24

33

C

onne

ctin

g R

od R

ing

4 K

6U-5

10

fo

r K6U

L or

K6U

AL

K

6UL-

324

• 34

C

onne

ctin

g R

od B

ushi

ng

2 K

6U-5

11

• 73

R

ope

Dru

m L

arge

Sea

l

K6U

-137

35

Cra

nk V

alve

End

Bea

ring

K

U-5

18

• 74

R

ope

Dru

m S

mal

l Sea

l

20-1

37A

•

36

Cra

nk S

plin

ed E

nd B

earin

g

KU

-895

•

75

Dru

m B

earin

g 2

K6U

-466

V

alve

Che

st A

ssem

bly

K

6U-A

545

75

A

Bea

ring

Ret

aine

r 2

23-4

06

37

V

alve

Che

st

K

6U-5

45

76

P

lane

t Gea

r Sha

ft 3

K6U

-787

38

G

reas

e Fi

tting

2

23-1

88

77

R

ope

Set

Scr

ew

2 K

6U-3

81

39

Bra

ke In

let P

lug

2 D

02-4

02

78

P

lane

t Gea

r 3

K6U

-K73

2

K6U

PA

RT

S L

IST

∗ N

OT

ILLU

STR

ATE

D

⊗ W

hen

orde

ring

a M

otor

Ass

embl

y or

Mot

or C

ase,

the

mod

el o

f the

win

ch m

ust b

e sp

ecifi

ed o

n th

e or

der t

o as

sure

that

the

nam

e pl

ate

on th

e ne

w M

otor

Cas

e is

sta

mpe

d w

ith th

e

c

orre

ct m

odel

sym

bol.

• T

o ke

ep d

ownt

ime

to a

min

imum

, it i

s de

sira

ble

to h

ave

on h

and

certa

in re

pair

parts

. We

reco

mm

end

that

you

sto

ck o

ne (p

air o

r set

) of e

ach

part

indi

cate

d by

a b

ulle

t (•)

for e

very

fou

r too

ls in

ser

vice

.

Ite

m N

o.

Des

crip

tion

of P

art

Uni

t Tot

al

Part

Num

ber

Ite

m N

o.

Des

crip

tion

of P

art

Uni

t Tot

al

Part

Num

ber

• 79

Pla

net G

ear B

earin

g

6 K

6U-7

88

11

2 G

ear C

ase

Cov

er C

ap S

crew

9

215-

148

80

P

lane

t Gea

r Spa

cer

6 K

6U-7

43

11

3 G

ear C

ase

Cov

er C

ap S

crew

Was

her

9 D

10-3

22

81

P

lane

t Gea

r Ret

aine

r 3

K6U

-362

114

Long

Bra

ke B

and

K

6U-2

52

82

D

rum

Thr

ust P

late

3

K6U

-469

•

115

Lo

ng B

rake

Lin

ing

K

6U-2

55

83

D

rum

Sha

ft

116

B

rake

Lin

ing

Long

Riv

et

9 K

6U-1

57

fo

r K6U

or K

6UA

K6U

-459

117

B

rake

Lin

ing

Sho

rt R

ivet

32

K

6U-1

56

fo

r K6U

L or

K6U

AL

K

6UL-

459

• 11

8 S

hort

Bra

ke B

and

K

6U-1

52

84

In

term

edia

te G

ear

K

6U-K

364

11

9

Sho

rt B

rake

Lin

ing

K

6U-1

55

• 85

Inte

rmed

iate

Gea

r Bea

ring

2

K6U

-366

120

B

rake

Lin

ing

Sho

rt R

ivet

17

K

6U-1

56

85

A

B

earin

g R

etai

ner

2 23

-406

121

B

rake

Lin

ing

Long

Riv

et

9 K

6U-1

57

86

M

otor

Sha

ft

122

Bra

ke L

ever

231-

715

fo

r K6U

or K

6UA

K6U

-316

123

B

rake

Lev

er B

olt

2 D

10-3

12

fo

r K6U

L or

K6U

AL

K

6UL-

316

12

4

Bra

ke L

ever

Bol

t Nut

2

WF1

71-1

3

87

Mot

or P

inio

n K

ey

E

EG

-768

Bra

ke L

ever

Scr

ew

R

0H-3

54

88

M

otor

Sha

ft N

ut

21

5-65

125

Bra

ke L

ever

Ext

ensi

on

23

1-62

5

89

Mot

or S

haft

Nut

Loc

k

215-

66

12

6 B

rake

Adj

ustin

g S

crew

231-

719

• 90

M

otor

Sha

ft B

earin

g

215-

55

12

7 B

rake

Adj

ustin

g N

ut

D

01-3

41A

91

Mot

or S

haft

Pin

ion

12

8 B

rake

Tru

nnio

n

215-

159

f

or K

6U o

r K6U

L

K

6U-3

19

12

9 B

rake

Bra

cket

Pin

K6U

-147

for

K6U

A o

r K6U

AL

K

6UA

-319

130

Bra

cket

Pin

Cot

ter

2 D

02-3

30

92

M

otor

Pin

ion

Thru

st W

ashe

r

K6U

-397

131

Bra

ke A

ncho

r Pin

2

K6U

-206

93

Driv

e S

haft

K

6U-3

58

13

2 A

ncho

r Pin

Cot

ter

4 D

02-3

30

94

Driv

e G

ear K

ey

23

-70

13

3 B

rake

Sup

port

K

6U-1

61A

95

D

rive

Sha

ft N

ut

21

5-73

134

Bra

ke S

uppo

rt P

in

K

6U-2

06

96

Driv

e S

haft

Nut

Loc

k

215-

74

13

6 B

rake

Sup

port

Cot

ter

2 D

02-3

30

• 97

D

rive

Sha

ft O

uter

Bea

ring

21

5-63

∗ E

xhau

st M

uffle

r

KU

-674

•

98

Driv

e S

haft

Inne

r Bea

ring

21

5-41

∗ W

inch

Nam

epla

te

D

U-3

01R

99

Driv

e G

ear

∗

Nam

epla

te S

crew

4

R4K

-302

for K

6U o

r K6U

L

K6U

-357

∗ C

autio

n P

late

TA-1

47A

for K

6UA

or K

6UA

L

K6U

A-3

57

∗

Cau

tion

Pla

te S

crew

4

R4K

-302

100

Driv

e G

ear S

pace

r

K6U

-356

∗ R

ope

Dire

ctio

n P

late

DU

-32

10

1 R

ing

Gea

r

K6U

-781

10

2 R

ing

Gea

r Sho

rt C

ap S

crew

215-

148

103

Rin

g G

ear L

ong

Cap

Scr

ew

5 21

00-4

57

104

Rin

g G

ear C

ap S

crew

Loc

k W

ashe

r 6

D10

-322

10

5 G

ear C

ase

K

6U-3

53

106

G

ear C

ase

Cov

er D

owel

HU

-627

10

7

Dru

m S

haft

Long

Set

Scr

ew

K

6U-8

68

108

G

reas

e P

lug

22

SR

-165

10

9

1 ¼

” Pip

e P

lug

E

5UD

-947

11

0 G

ear C

ase

Cov

er

K

6U-3

52

111

G

reas

e P

lug

22

SR

-165

∗

E

ccen

tric

Sha

ft Lo

ck S

crew

J3-8

23

∗

Gea

r Cov

er P

lug

K

6U-7

28

∗

Gea

r Cov

er P

lug

Sea

l

HU

-730

∗

G

reas

e Fi

tting

23-1

88

K6U

PA

RT

S L

IST

∗ N

OT

ILLU

STR

ATE

D

⊗ W

hen

orde

ring

a M

otor

Ass

embl

y or

Mot

or C

ase,

the

mod

el o

f the

win

ch m

ust b

e sp

ecifi

ed o

n th

e or

der t

o as

sure

that

the

nam

e pl

ate

on th

e ne

w M

otor

Cas

e is

sta

mpe

d w

ith th

e

c

orre

ct m

odel

sym

bol.

• T

o ke

ep d

ownt

ime

to a

min

imum

, it i

s de

sira

ble

to h

ave

on h

and

certa

in re

pair

parts

. We

reco

mm

end

that

you

sto

ck o

ne (p

air o

r set

) of e

ach

part

indi

cate

d by

a b

ulle

t (•)

for e

very

fou

r too

ls in

ser

vice

.

Ite

m N

o.

Des

crip

tion

of P

art

Uni

t Tot

al

Part

Num

ber

Ite

m N

o.

Des

crip

tion

of P

art

Uni

t Tot

al

Part

Num

ber

AU

TO B

AN

D B

RA

KE

PAR

TS

DIS

ENG

AG

ING

CLU

TCH

PA

RTS

1 A

ir C

ylin

der

1 H

UR

-720

500

Driv

e S

haft

K6U

-C35

8

2 A

ir C

ylin

der R

od E

nd C

levi

s 1

HU

R-7

19

50

1

Clu

tch

Jaw

Loc

k P

lug

H

U-8

64

3

Red

ucer

1

FP50

014

50

2

Clu

tch

Jaw

Loc

k S

prin

t

K4U

-863

4 B

rake

Lev

er

1 K

6UR

-718

503

C

lutc

h Ja

w L

ock

Bal

l

K4U

-863

5 C

ylin

der C

ompr

essi

on S

prin

g 1

HU

R-7

26

50

4 D

rive

Gea

r Was

her R

etai

ner

K

6U-3

62

6

Air

Cyl

inde

r Piv

ot P

in ¾

Dia

met

er

2 40

1941

-10

• 50

5 C

lutc

h Ja

w

K

4U-5

68

7

Cot

ter P

in

4 A

G76

865

50

6 D

rive

Gea

r Was

her

2 K

6U-3

63

8

Hex

Hea

d C

ap S

crew

Pla

ted

2 FQ

0408

6

507

Clu

tch

Ecc

entri

c S

haft

K

6U-8

57

9

Lock

Was

her P

late

d 2

FQ11

250

50

8

Ecc

entri

c P

in L

ock

Scr

ew

H

U-8

60

10

B

rake

Cyl

inde

r Bra

cket

1

K6U

R-7

21

50

9

Clu

tch

Ecc

entri

c P

in

H

U-8

59

11

S

treet

El

2 FP

5003

5

510

C

lutc

h E

ccen

tric

Rol

ler

H

U-8

58

12

S

top

Tube

Cor

ed

1 40

2757

511

Driv

e G

ear

13

A

ir C

ylin

der R

od P

in

1 40

1941

-11

for

K6U

, K6U

L

K6U

-C35

7

14

Qui

ck E

xhau

st V

alve

1

K6U

R-7

33

for

K6U

A, K

6UA

L

K6U

A-C

357

15

D

ust E

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RAM P/N LB80040R FILTER

Specifications Pipe Size 1 1/4

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

LB80045R Lubricator Components

1 Body 19 Siphon Tube 2 Housing 20 “O” Ring 3 Clamp Ring 21 Damper Frame 4 Bowl 22 Packing5 “O” Ring 23 Screw6 Fill Plug 24 Damper7 “O” Ring 25 Damper Holder 8 Sight Dome 26 Damper Retainer 9 Drip Tube 27 Check Ball 10 Packing 28 Check Ball Spring 11 Needle Stud 29 Screw12 Needle Guide 30 Guide Rod 13 Steel Ball 31 Float14 “O” Ring 32 Guide Pipe 15 “O” Ring 33 Indicator16 Element 34 Packing17 Check Ball 35 Damper Holder 18 Siphon Tube Screw 36 Bowl Guard

LB80045 LUBRICATOR

LB80045R Technical Specifications

Max Supply Pressure 1.5 MPa / 220 PSI Max Operating Pressure 1 MPa / 145 PSI Operating Temp Range 5 ~ 60 C / 40 ~ 140 F Recommended Lubricant Turbine Oil #1 (ISO VG32) Bowl PolycarbonatePipe Size 11/4, 11/2 Min Flow for Oil Drip 650Oil Capacity (cm3) 500Flow Rate 12500

LB80045R Flow Characteristics

1 1/4

LB80045 LUBRICATOR

FLOW CHARACTERISTICS

RAM P/N LB80050 REGULATOR

SPECIFICATIONS

Port Size 1 ½

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 Conditions: Supply Pressure 100 psig

PRESSURE CHARACTERISTICS Supply Pressure – 100 psig Secondary Pressure – 30 psig (0.2 Mpa) Flow – 0.7 SCFM (20l/min)

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

4.96 (126)

8.54 (216.9)

2.95 (75)

4.33 (110)

3.86 (98)

0.20 (5

RAM P/N LB40024 Pressure Gauge

Size ------------ 50mm(2”)

Thread Location -------- CBM

Thread Size ------------ ¼” NPT Material ------------- Urban White

(Case/Socket) ABS/Polymid Units ---------- Mpa & psi

Scale --------- 0 – 160 psi

A B C D E F G H J K 1.93 1.04 - 1.87 - - - - .55 ¼ NPT

K6U Air WinchRAM Winch & Hoist 10/09