RN60P Service Manual
Contents
1. SA 4250 ITEM DESCRIPTION QTY PART 1 INPUT CARRIER 1 43183 2 INPUT PLANET GEAR 3 42877 3 NEEDLE BEARING 3 30484 4 RETAINING RING 3 41715 5 PLANET PIN 3 41760 6 THRUST WASHER 6 40264 7 PLATE 1 42954 81575 item 22 B SA 4228 ITEM DESCRIPTION QTV PART 1 INPUT CARRIER 1 42925 2 INPUT PLANET GEAR 3 42877 3 NEEDLE BEARING 3 30484 4 RETAINING RING 3 41715 5 PLANET PIN 3 42950 6 THRUST WASHER 6 40264 7 PLATE 1 42954 81575 item 23 A SA 4229 ITEM DESCRIPTION QTY PART 1 SECONDARY CARRIER 1 42926 2 SECONDARY PLANET GEAR 3 42876 3 BEARING 6 41717 4 RETAINING RING 3 41716 5 PLANET PIN 3 42951 6 RACE 6 939249 7 PLATE 1 42957 81575 24 A and B SA 4230 ITEM DESCRIPTION QTY PART 1 OUTPUT CARRIER 1 42927 2 OUTPUT PLANET GEAR 3 42878 3 NEEDLE BEARING 9 939247 4 RETAINING RING 3 41901 5 PLANET PIN 3 42952 6 RACE 6 27219 7 PLATE 1 42957 8 SNAP RING 1 43699 fish Tulsa Winch VISCOSITY CHART IEMATI AGMA MBE RANKCASE OIL2. es Tulsa Winch TORQUE SPECIFICATIONS CHART HEX HEAD CAP SCREWS Grade 5 ji Grade 8 Nominal Dia Threads Per Ft Lbs Ft Lbs Inch 3 8 16 36 42 42 48 24 41 47 48 54 7 16 14 54 62 63 71 20 65 73 76 84 1 2 13 80 90 100 110 20 100 110 120 130 9 16 12 105 115 125 135 18 125 135 150 160 5 8 11 170 180 200 210 18 195 205 230 240 3 4 10 285 295 330 340 16 340 350 400 410 7 8 9 495 505 580 595 14 580 595 685 700 1 8 685 700 805 820 14 825 840 965 980 1 1 8 7 1045 1060 1500 1525 12 1240 1260 1680 1705 21 TITLE
3. us Tulsa Winc RUFNEK 60 100 SERVICE MANUAL MODEL L ia 2 3 INTRODUCTION AND THEORY OF 4 MAINTENANCE i e 4 GENERAL DISASSEMBLY 222 5 MOTOR 5 55 5 B BRAKE SECTION _ 1 5 DRUM SECTION DISASSEMBLY 6 GEAR SECTION DISASSEMBEY 6 PLANET SET DISASSEMBIEY 12 7 BLOCKED PISTON COVER DISASSEMBLY 8 BLOCKEDIRISTONICOVERIASSEMBL _ _ GP 8 GENERAIPASSEMBLY cece gees 9 F GEARIENDIASSEMBE 9 GADROMSEOMON ASSEMBL VA a a 9 H BRAKE SE INEOMASSEMIBI ATA MD 10 TROUBLE 11 RUFNEK 60 BILL OF MATERIAL amp 12 RUFNEK 100 BILL OF MATERIAL amp 15 RUFNEK 60 SUB ASSEMBLY BILL OF MATERIAL 22 2 2 4440000 0 000000 18 RUFNEK 100 SUB ASSEMBLY BIL
4. 1B and inspect the o ring 26B and bearing 27 This is a blocked piston assembly and the piston 48 is not in use You may want to leave the piston and spacer 108B in the housing and bypass inspection Remove the thrust washer 75B and sun gear 6B BLOCKED PISTON COVER ASSEMBLV Inspect and replace anv worn parts With the piston 4B and the spacer 108B in place assemble the sun gear 6B thrust washer 75B and spring 2B Install the cover 1B on top of the spring and align the bolt holes Applv pressure straight down until vou can get all six capscrews 25B started at least 2 3 threads Torque all six capscrews to proper specification GENERAL ASSEMBLV F GEAR END ASSEMBLV Bolt gear housing 10 looselv into both frames 73 74 When reassembling use a lot of grease or oil on the areas such as the thrust washer o ring and seals First slide thrust washer 38 onto shaft Next install the output gear set 24 into the gear housing 10 Rotate the thrust washer 24 5 or 24 7 in position to allow installation of the snap ring 24 8 or 24 9 into the shaft groove Push the gear set and shaft back into the housing until it stops against the thrust washer 38 Then install snap ring onto output shaft 20 Note Line up all three planet gears in the output gear set with the gear housing as it starts into
5. 77 Note which frame the mounting bolts are on for re assembly Inspect and replace any worn parts of this assembly Remove the outer thrust collar 131 by removing two set screws 130 Remove the thrust ring 128 and clutch plate 15 by removing six capscrews 129 Remove the sliding clutch 13 coupler 12 keys 47 and the inner thrust collar 46 Remove the drum using a hoist Inspect the bushings 19 in both ends of the drum Note You may also inspect the bushing and seal 40 41 that are located in the end of the brake housing Inspect or replace the drum clutch 14 at this time by removing six capscrews 45 If you replace the clutch make sure to torque the capscrews to the specified torque upon re assembly D GEAR SECTION DISASSEMBLY Drain the oil at the bottom of the gear housing by removing the plug 31 To disassemble the gear section you must start with the outer cover Remove the capscrews 30 and cover Note If you have the blocked piston cover assembly take it off as an assembly and see Service of Blocked Piston Cover Assembly Inspect the o ring 33 bearing 27 and spacer 127 Remove and inspect the outer thrust washer 34 and replace if necessary Remove input gear set 22A the inner thrust washer 34 sun gear 7 and the secondary gear set 23 Remove the thrust washer 37 and inspect for wear Replace if necessary Remove the primary housing 9 by removing eight cap
6. 39 located at the top of the gear housing item 10 Remove the drain plug item 31 located at the bottom center of the gear housing Examine the used oil for signs of significant metal deposits and then dispose of it in a proper manner Reinstall the drain plug and fill the gearbox with the proper amount of new Mobilube SHC SAE 75W 90 gear lube through the fill hole Replace the fill plug Make sure the breather item 93 is operational and replace if necessary Drain the brake section by removing the drain plug and breather in the brake cover item 18 Inspect the oil for signs of metallic particles and or burning and re install the drain plug Fill with one half to one pint of automatic transmission fluid or hydraulic oil and replace the breather OIL CAPACITIES GENERAL DISASSEMBLV A MOTOR DISASSEMBLV Drain the oil from the brake assembly by removing the plug 94 from brake cover 18 Remove hoses 92A 109 amp 112 Remove the counterbalance block 79 manifold block 119 and switch 118 from the motor by removing the four capscrews 110 Remove the counterbalance valve 114 from the counterbalance block 79 and inspect the metering hole to make sure it is not obstructed Also inspect the o rings to insure that they are not flat or cut Replace if necessary Motors and counterbalance valves are not serviceable in the field Return them to an authorized dealer for service B BRAKE SECTION DISASSEMBLY Evenly
7. Service the brake section and replace worn parts RUFNEK 60 BILL OF MATERIAL A amp ITEM NO PART NO QTV DESCRIPTION 1B 43065 1 PISTON COVER 2B 42908 1 SPRING 3A 43180 1 COVER 3B 43055 1 PISTON HOUSING 4B 42910 1 PISTON 5B 43067 1 SHIFT PLATE 6A 43179 1 SUNGEAR 6B 42998 1 SUNGEAR 7 42999 1 SECONDARY SUNGEAR 8 42996 1 OUTPUT SUNGEAR 9 43031 1 PRIMARV GEAR HOUSING 10 43056 1 GEAR HOUSING 11 43059 1 DRUM 12 43071 1 COUPLER 13 43521 1 SLIDING CLUTGH 14 43062 1 CLUTCH 15 43398 1 CLUTCH PLATE 16 43058 1 BRAKE HOUSING 17 43577 1 AIR CYLINDER 18 43419 1 BRAKE COVER 19 43032 2 BUSHING 20 42976 1 OUTPUT SHAFT 21A 43161 1 INPUT SHAFT 21B 42977 1 INPUT SHAFT 22A 4249 1 INPUT GEAR SET 22B 4237 1 INPUT GEAR SET 23 4235 1 SECONDARY GEAR SET 24 4236 1 OUTPUT GEAR SET 25B 30205 4 CAPSCREW 26B 42232 2 O RING 27 43068 1 BEARING 28B 32743 1 O RING 29B 41903 3 RETAINING RING 30 20524 10 CAPSCREW 31 31582 1 O RING PLUG 32B 41307 1 O RING PLUG 33 43120 1 O RING 34 41722 2 THRUST WASHER 35 28060 12 CAPSCREW 36 42841 1 O RING 38 43066 1 THRUST WASHER 39 42978 1 O RING PLUG SPECIAL 40 43033 2 BUSHING 41 43057 2 OIL SEAL 42 20517 2 PIN MODEL 10 80 43 21163 1 U BOLT 45 20886 6 CAPSCREW 46 43522 1 THRUST COLLAR 47 43070 3 KEY 49 43073 1 OIL SEAL 50 26340 1 BALL BEARING 51 42941 8 CA
8. When installing the blocked piston cover assembly rotate it back and forth until oo the sun gear lines up with the planet gears in the input gear set and then secure the eight capscews 30 to the proper torque On the motor end lightly tap on the input shaft until it seats into the bearing 27 in the cover Note In both cover versions assistance may be needed in holding the input shaft while the cover is installed G DRUM SECTION ASSEMBLY After inspecting and replacing the necessary parts you can reinstall the drum 11 This part is very heavy and you will need the assistance of a hoist With the weight of the drum supported install the brake band assembly 77 and reattach the capscrews 91 nut and washers 85 8 86 brake band air cylinder 76 can be reattached later if not all together Install the inner thrust collar 46 making sure the half moon slots are lined up with the key slots in the output shaft 20 Tap the three keys 47 into their slots in the output shaft and slide the coupler 12 into place Install the sliding clutch 13 clutch plate 15 and thrust ring 128 by installing six capscrews 129 Then install the outer thrust collar 131 Again align the half moon slots with the keys Holding tightly against keys lock down the set screws 130 Slide the brake housing 16 into place The air line from the brake band air cylinder can be attached at this time Install the four caps
9. bushing 68 Slide the brake driver off the drive coupling Note Notice the direction of lock up on the clutch for re assembly the driver coupling and brake driver for wear Replace if necessary If the drum bushings or seals need to be replaced see the drum section of this manual before re assembly of the brake C DRUM SECTION DISASSEMBLV To remove the drum first disconnect the cable from the u bolt 43 and lay aside If removing the drum from the motor end with the motor and brake disassembled first remove the eight capscrews 51 eight roll pins 103 and air cylinders covers 96 97 on the air cylinders 17 amp 125 Note you may need to remove the air lines Mark them for re assembiv You will need to support the weight of the drum with a hoist Remove the four capscrews 70 and the nuts and washers 71 72 on the bottom of the brake housing 16 At this time you will need to remove two capscrews 91 nut and washers 85 86 from the frames 73 or 74 Do not remove air cylinder 76 yet Disconnect the air line from the backside of the brake housing 16 that goes to the band brake cylinder If a complete tear down is not necessary make sure the output shaft 20 or input shaft 21 does not move during removal of the drum With help from a hoist or another person slide the whole brake housing out from the drum until you are free of everything You can now remove the brake band assembly
10. remove the four capscrews 60 that hold the brake cover in place Spring pressure will raise the cover up as the capscrews are loosened Carefully remove the cover 18 from the brake housing 16 Inspect the o ring 61 for damage Remove the springs 59 from the piston 54 and check the free height Each spring should measure at least 1 200 inches with no force on them Remove the piston 54 by installing two pieces of 3 8 16NC all thread into the two holes in the top of the piston and run in evenly until the piston is clear of the housing An alternate way of removing the piston is to use a portable hydraulic power unit or air to gently pressurize the brake cavity to remove the piston from the brake housing 16 Inspect o rings 55 57 and back up rings 56 58 on the piston Replace if necessary Grasp the brake driver clutch assembly assembled items 64 65 66 67 68 69 95 and remove it from the brake housing Remove the stator plates 52 and friction discs 53 from the brake housing and check them for excessive wear Replace if necessarv Be sure to check the top stator plate for scoring caused by the removal of the piston and polish if necessary Friction discs should measure no less than 055 in thickness and stator plates should measure no less than 068 in thickness To disassemble the brake driver clutch assembly remove the retaining ring 66 from either end of the driver Then remove the race 67 and
11. L OF MATERIAL 02 0440 mnn mnn 19 VISCOSITY GHAR Pirta ea ite cite tia eee ei ep A nae 20 TORQUE SPECIFICATIONS 21 EXPLODED ISOMETRIG ASS Y pe e SM 22 SEL 0009 REV 3 MODEL CODE BASIC MODEL RN60 RN100 LEFT RIGHT MOUNT SPOOL OVER UNDER DRUM MOTOR TYPE SINGLE SPEED GEAR MOTOR TWO SPEED GEAR MOTOR SINGLE SPEED GEROLER TWO SPEED GEROLER PISTON VANE NO MOTOR MANUAL TWO SPEED GEARBOX 1 WITHOUT 2 WITH IWARNINGI FAILURE TO HEED THE FOLLOWING WARNINGS MAV RESULT IN SERIOUS INJ OR DEATH Tulsa Winches are not to be used to lift hoist or move people If your task involves lifting or moving people you MUST use the proper equipment not this winch Cable anchors on Tulsa Winches are not designed to hold the rated load of the winch You must keep at least five 5 wraps of cable on the drum to insure that the cable doesn t come loose Stay clear of the suspended loads and of cable under tension A broken cable or dropped load can cause serious injury or death Make sure that all equipment including the winch and cable is maintained properly Avoid shock loads This type of load imposes a strain on the winch many times the actual weight of the load and can cause failure of the cable or of the winch Win
12. PSCREW 52 42148 8 STATOR PLATE 53 32765 7 FRICTION DISC 54 42942 1 BRAKE PISTON 55 42335 1 O RING 56 42336 1 BACKUP RING 57 32186 1 O RING 58 42337 1 BACKUP RING 59 42230 12 BRAKE SPRING 61 33094 1 O RING 62 34003 1 O RING 6 43165 1 HYDRAULIC MOTOR 2SPD 63B 43162 1 HVDRAULIC MOTOR 1SPD 64 43072 1 INPUT DRIVER 66 26980 2 RING RETAINING 67 41723 2 RACE 68 41743 2 BUSHING 69 42947 1 BRAKE DRIVER 70 30203 8 CAPSCREW 71 20318 8 NUT 72 20559 8 LOCK WASHER 73 43076 1 L H FRAME 74 43077 1 R H FRAME 75B 42949 1 THRUST WASHER 76 42929 1 BRAKE AIR CYLINDER 77 4238 1 BRAKE BAND ASSY 79 42029 1 BLOCK C B 80B 42030 1 HOSE ASSY 81B 42259 1 LONG MALE ELBOW 82 42438 2 FITTING TEE 83 41838 2 STRAIGHT ADAPTER 84 42089 3 ELBOW 85 20521 4 NUT 86 20518 2 LOCKWASHER 87A 32182 2 O RING 87B 32182 1 O RING 88B 42211 1 SAE BLOCK 89 40546 4 CAPSCREW 90 42955 1 MOUNTING BRACKET 91 20525 2 CAPSCREW 92A 42031 2 HOSE ASSY 92B 42032 2 HOSE ASSY 93 13050 2 BREATHER 94 21684 2 PIPE PLUG 95 41759 1 CLUTCH 96 42970 1 AIR CYL COVER LH 97 42971 1 AIR CYL COVER R H 98 42979 1 AIR SHIFT KIT 99 43050 2 ADJUSTING NUT 100 42987 1 DRUM BRAKE LABEL 101 42986 1 CLUTCH OUT LABEL 102 42985 1 CLUTCH IN LABEL 103 43078 8 ROLL PIN 104 939243 1 CLEVIS PIN 105 20514 1 CO
13. TER STRAIGHT 123 43459 1 HOSE ASS Y 124 42866 1 GREASE ZERK 125 43578 1 AIR CYL W SWITCH 127 43288 1 SPACER 128 43505 1 RING THRUST 129 31550 6 CAPSCREW F H 130 20515 2 SET SCREW 131 43696 1 THRUST COLLAR 132 21128 2 GREASE ZERK 133 44338 1 HOUSING BEARING RN100 134 42932 1 BEARING BALL 135 44323 2 RING RETAINING 136 29162 2 BEARING BALL 137 29043 1 RING RETAINING 138 44337 1 DRIVER INPUT 139 44335 1 DRIVER BRAKE 141 4387 1 KIT CLUTCH SPRAG RN100 RUFNEK 60 SUB ASSEMBLY BILL OF MATERIAL 81574 item 24 A and B SA 4236 ITEM DESCRIPTION QTY PART NO 1 OUTPUT CARRIER 1 43012 2 OUTPUT PLANET GEAR 3 43015 3 PLANET PIN 3 41747 4 RETAINING RING 3 41716 5 PLATE 1 43701 6 BEARING 6 41717 7 SPACER 3 41739 8 RACE 6 939249 9 SNAP RING 1 27011 81574 item 23 and B SA 4235 ITEM DESCRIPTION QTV PART NO 1 SECONDARV CARRIER 1 43013 2 SECONDARY PLANET GEAR 3 43014 3 BEARING 6 30484 4 RETAINING RING 3 41715 5 PLANET PIN 3 42184 6 RACE 6 28771 7 PLATE 1 43181 81574 item 22 A and B SA 4249 ITEM DESCRIPTION QTY PART NO 1 INPUT CARRIER 1 43016 2 INPUT PLANET GEAR 3 42304 3A PLANET PIN 3 41760 3B PLANET PIN 3 42950 4 RETAINING RING 3 41715 5 BEARING 3 30484 6 RACE 6 28771 7 PLATE 1 43181 RUFNEK 100 SUB ASSEMBLY BILL OF MATERIAL 81575 item 22
14. TTER PIN 108B 43085 1 SPACER 109A 42495 1 HOSE 110 43372 4 CAPSCREW 111 42997 1 SUN GEAR 112 42030 1 HOSE 113 41719 1 PLUG 114 41867 1 COUNTERBALANCE VALVE 115 32411 1 PLUG 115B 42225 1 PLUG 116 42223 1 CHECK VALVE 117 42263 4 CAPSCREW 118 43367 1 SWITCH 119 43368 1 MANIFOLD BLOCK 121 42033 1 SWIVEL TEE 122 40280 1 STRAIGHT ADAPTER 123 43459 1 HOSE 124 42866 1 ZERK GREASE 125 43578 1 AIR CYL W SWITCH 127 43289 1 SPACER INPUT 128 43257 1 RING THRUST 129 31550 1 SCREW FLAT 130 20515 2 SET SCREW 131 43697 1 THRUST COLLAR 132 21128 2 ZERK GREASE 133 4386 1 KIT CLUTCH SPRAG RN60 134 44336 1 HOUSING BEARING RN60 135 44324 1 BEARING NEEDLE 136 44325 1 RING RETAINING 137 44323 2 RING RETAINING 138 29162 2 BEARING BALL 139 44334 1 DRIVER INPUT RN60 140 44335 1 DRIVER BRAKE RN60 130 RUFNEK 100 BILL OF MATERIAL A amp B ITEM NO PART NO QTV DESCRIPTION 1B 42907 1 PISTON COVER 2B 42908 1 SPRING 3A 43185 1 COVER 3B 42909 1 PISTON HOUSING 4B 42910 1 PISTON 5B 42911 1 SHIFT PLATE 6A 43125 1 SUNGEAR 6B 42912 1 SUNGEAR 7 42913 1 SECONDARY SUNGEAR 8 42914 1 OUTPUT SUNGEAR 9 42915 1 PRIMARV GEAR HOUSING 10 42916 1 GEAR HO
15. USING 11 42917 1 DRUM 12 42918 1 COUPLER 13 43506 1 SLIDING CLUTCH 14 43504 1 CLUTCH 15 43503 1 CLUTCH PLATE 16 42922 1 BRAKE HOUSING 17 43577 1 AIR CYLINDER 18 43419 1 BRAKE COVER 19 42868 2 BUSHING 20 42869 1 OUTPUT SHAFT 21A 43123 1 INPUT SHAFT 21B 42870 1 INPUT SHAFT 22A 4250 1 INPUT GEAR SET 22B 4228 1 INPUT GEAR SET 23 4229 1 SECONDARY GEAR SET 24 4230 1 OUTPUT GEAR SET 25B 30205 6 CAPSCREW 26B 42232 2 O RING 27 42931 1 BEARING 28B 32743 1 O RING 29B 41903 3 RETAINING RING 30 20524 12 CAPSCREW 31 41719 2 O RING PLUG 32 41307 1 O RING PLUG 33 28947 1 O RING 34 42934 2 THRUST WASHER 35 28212 8 CAPSCREW 36 32368 1 O RING 37 42935 1 THRUST WASHER 38 42936 1 THRUST WASHER 39 42978 1 O RING PLUG SPECIAL 40 42930 2 BUSHING 41 42928 2 OIL SEAL 42 20517 2 PIN MODEL 10 80 43 42937 1 U BOLT 45 21644 6 CAPSCREW 46 42938 1 THRUST COLLAR 47 42939 3 KEY 49 42948 1 OIL SEAL 50 42932 1 BEARING 51 42941 8 CAPSCREW 52 42148 8 STATOR PLATE 53 32765 7 FRICTION DISC 54 42942 1 BRAKE PISTON 55 42335 1 O RING 56 42336 1 BACKUP RING 57 32186 1 O RING 58 42337 1 BACKUP RING 59 42230 12 BRAKE SPRING 60 28060 4 CAPSCREW 61 33094 1 O RING 62 34003 1 O RING 6 43153 1 HYDRAULIC MOTOR 2SPD 63B 42953 1 HYDRAULIC MOTOR 1SPD 64 42944 1 INPUT DRI
16. VER 65 29043 1 RETAINING RING 66 26980 2 RETAINING RING 67 41723 2 RACE 68 41743 2 BUSHING 69 42947 1 BRAKE DRIVER 70 20650 8 CAPSCREW 71 20653 8 NUT 72 20652 8 LOCK WASHER 73 42946 1 L H FRAME 74 42945 1 R H FRAME 75B 42949 1 THRUST WASHER 76 42929 1 BRAKE AIR CYLINDER 77 4231 1 BRAKE BAND ASSY 79 42029 1 C B BLOCK 80B 42495 1 HOSE ASSY 81 42259 1 LONG MALE ELBOW 82 42438 2 FITTING TEE 83 41838 2 STRAIGHT ADAPTER 84 42089 3 ELBOW 85 20521 2 NUT 86 20518 2 LOCKWASHER 87A 32182 2 O RING 87B 32182 1 O RING 88B 42211 1 SAE BLOCK 89B 29421 1 CAPSCREW 90 42955 1 MOUNTING BRACKET 91 29472 2 CAPSCREW 92A 42031 2 HOSE ASSY 92B 42032 1 HOSE ASSY 93 13050 2 BREATHER 94 21684 1 PIPE PLUG 95 41759 1 CLUTCH 96 42970 1 AIR CYL COVER L H 97 42971 1 AIR CYL COVER R H 98 42979 1 AIR SHIFT KIT 99 43050 2 ADJUSTING NUT 100 42987 1 DRUM BRAKE LABEL 101 42986 1 CLUTCH OUT LABEL 102 42985 1 CLUTCH IN LABEL 103 43078 8 ROLL PIN 104 939243 1 CLEVIS PIN 105 20514 1 COTTER PIN 108B 43085 1 SPACER 109 42495 1 HOSE 110 43372 4 CAPSCREW 112 42030 1 HOSE ASS Y 113 41719 1 PLUG 114 41867 1 VALVE C B 115A 32411 1 PLUG 115B 42225 1 PLUG 116 42223 1 CHECK VALVE 117 42263 4 CAPSCREW 118 43367 1 SWITCH SOLONOID 119 43368 1 BLOCK MANIFOLD 121 42033 1 TEE SWIVEL 122 40280 1 ADAP
17. ch operators must be trained in the proper safe operation of the winch Do not use EP type gear lubes in the brake section of this winch EP lubes may prevent the clutch from locking up causing a load to fall and resulting in property damage personal injury or death The hydraulic system should use only high quality hydraulic oils from reputable suppliers These oils should contain additives to prevent foaming and oxidation in the system All winch hydraulic systems should be equipped with a return line filter capable of filtering 10 micron particles from the system INTRODUCTION AND THEORY OF OPERATION The Rufnek series planetary winch is designed to use a high speed gear motor driving through a multiple disc brake through three planet sets to the cable drum The multiple disc brake is spring applied and hydraulically released through a port in the brake housing During inhaul the brake is not released since the load is driven through the one way cam clutch bypassing the brake When the load comes to a stop the cam clutch locks up and the load is prevented from moving by the brake The brake and brake valve receives its signal any time the winch is in pay out With the brake fully open at about 340 PSI the brake valve will open and dynamically control the lowering of the load MAINTENANCE Tulsa Rufnek series planetary winches like any other piece of machinery need to be periodically serviced and well maintained to insure prope
18. crews 70 nuts and washers 71 72 into the frames 73 74 Slide the clutch 13 out of gear so you can turn the drum freely and tighten all bolts through the frames to the proper torque specification Turn the drum to make sure it is not binding Install the sliding clutch air cylinders 17 and 125 and air cylinder covers 96 amp 97 to the brake housing with the four capscrews 51 on each side Readjust the adjusting nuts 99 on the clutch plate 15 Hook air to the cylinders and apply air both directions With the clutch fully engaged air applied there should be slight movement on the clutch plate both directions When adjusted properly tighten the jam nut on the end of the air cylinder to lock in place AAS THIS DIM FOR RN6O UNITS BUILT PRIOR TO 01 01 04 T RN100 1 380 1 410 THIS DIM FOR ALL RN100 UNITS MAA L BUILT BEFORE amp AFTER 01 01 04 SETTA 60 2 195 2 225 THIS DIM FOR RN60 UNITS BUIL H BRAKE SECTION ASSEMBLV Measure the distance as shown above If needed add shims part number 33324 and 994188 inside input driver 64 to achieve above noted dimension Note For RN60 units built after 01 01 04 measuring and shim
19. d at 340psi plus or minus 20psi Also check the brake for proper operation by applying 280psi to the brake port and adapting a torque wrench to the input shaft The torque in the payout should be 95 to 115 ft lbs Install the motor 63 and secure with the four capscrews 30 Tighten the capscrews to the proper torque Note Make sure you install the motor with the belly of it down and the case drain port up Install the counterbalance block Hook up the brake line to the top of the brake housing 16 Fill the brake and gearbox with the proper oil TROUBLE SHOOTING 1 PROBLEM Winch won t hold load SOLUTION Excessive back pressure in the svstem Check the svstem for restrictions and reduce the a backpressure b Brake discs are worn out Replace brake discs c Winch clutch is slipping Inspect the clutch and driver for wear and replace worn parts 2 PROBLEM Winch will not raise the load it should SOLUTION a Relief valve setting may be too low to allow proper lifting Increase relief valve pressure setting Note do not exceed recommended system pressures b Load being lifted may be more than the winch s rating Reduce the load or re rig to increase mechanical advantage 3 PROBLEM Oil leaks from the vent on the motor side of the winch SOLUTION a The motor shaft seal may have failed Replace this seal and reduce backpressure if that caused the shaft seal to fail b Brake piston seals may have failed
20. ming is done after installing the cover 18 as shown above Refer to Field Service Literature FSL 0017 for RN45 130 product enhancements to the driver clutch ass v Re assemble the driver clutch assembly making sure the clutch is installed properlv and checking to make sure the cam clutch is free turning in the pav in direction Install the driver clutch assembiv onto input shaft 21A Install the stator plates 52 and friction discs 53 starting with a stator plate and alternating between friction discs and stator plates until eight stator plates and seven friction discs are used Note Soak friction discs in hvdraulic oil before installation Coat the piston O D with oil or grease and install the piston into the brake housing bv gentiv tapping it down until it is seated making sure not to damage the o rings or back up rings stall the springs into the spring pockets working in a horizontal position coat the 10 AFTER 01 01 04 bottom of each spring with chassis lube to keep it in position Coat the o ring 61 with oil or grease and install it into the groove on the brake cover 18 Install the cover onto the brake housing using the capscrews 60 Then draw it down evenly alternating between opposite hex bolts Make sure that the cover is aligned properly with the brake housing to orient the motor as it should be Check the brake release with a portable hydraulic pump Full release should be obtaine
21. r operation Good maintenance consists of four steps 1 daily inspection to insure that there are oil leaks present and that all mounting bolts and other fasteners are tight and that the wire rope is in good condition 2 Changing the oil in both the gearbox and the brake section Severity of use will determine the need for oil changes but it should be checked at a minimum of every 500 hours Factors such as extremely dirty conditions or widely varying temperature changes may dictate even more frequent servicing 3 Lubing drum bushings and sliding clutch with grease thru grease fittings located on drum barrel and clutch 4 Complete teardowns and component inspections Again severity and frequency of use will determine how often this should be done the equipment that this winch is mounted to is subject to standards for this type of inspection then those standards must be followed If oil changes reveal significant metallic particles then a teardown and inspection must be made to determine the source of wear Tulsa Rufnek series of winches are shipped from the factory with Mobilube SHC SAE 75W 90 gear lube in the gearbox and automatic transmission fluid in the brake section This oil should be satisfactory for operation in ambient temperatures from 40 F to 110 F If your work calls for operation in temperatures outside this range contact Tulsa Winch for recommendations Gearbox oil is drained by removing the fill plug item
22. screws 35 Note The housing is very heavy Use caution when removing it After removing the primary housing inspect the o ring 36 Remove the sun gears 8 111 Rotate thrust washer 24 5 or 24 7 into alignment with snap ring 24 9 or 24 8 Remove snap ring from groove on shaft 20 Remove output gear set 24 Remove and inspect the thrust washer 38 Replace if necessary E PLANET SET DISASSEMBLY Remove the retaining rings from the planet pins Remove the pins from the carrier by carefully tapping them out Remove the planet gears thrust washers and bearings from the carriers Inspect the pins bearings and gear bores for evidence of wear and replace if necessary To re assemble output gear set first insert snap ring Next insert thrust plate into carrier of input or output gear set along with gears bearings and washers Being careful to line up the planet pins with the thrust washers and bearings Press the pin into the carrier If the pins are not lined up properly the thrust washer can be shattered during the pressing operation Replace retaining rings A BLOCKED PISTON COVER DISASSEMBLV Loosen the six capscrews 25B that secure the outer cover 1B This cover is spring loaded so the capscrews 25B will need to be loosened evenly The spring 2B is longer than the capscrews Use extreme caution After the capscrews 258 have been loosened remove the cover
23. the housing Install the output sun gear 8 111 the thrust washer 37 then the secondary gear set 23 Line up the teeth that are on the inside of the primary gear housing 9 with all three of the gears on the secondary gear set Push the primary gear housing 9 into place making sure not to cut the o ring 36 Install the eight capscrews 35 and torque them to specification Install the secondary sun gear 7 Making sure it is against the washer in the secondary gear set Attach the inner thrust washer 34 to the input gear set 22A Insert input gear set 22A making sure it is against the thrust washer 34 Put the outer thrust washer 34 in place and slip the input shaft 21 all the way though the output shaft 20 Let the input shaft stick out on the gear end so that all of the spline is showing Make sure the correct end is towards the gear end It will not work if it is backwards Slip the input sun gear 6A and race 127 onto the end of the input shaft 21 Push back on the input shaft and sun gear at the same time until the sun gear fits into the inside diameter of the three planet gears on the input gear set Put the cover on and secure the eight capscrews 30 making sure the o rings 33 is not cut If you have the blocked piston version after rebuild install it just as you would the other cover except when you slip the outer input sun gear on the shaft it is locked into the cover assembly
Download Pdf Manuals
Related Search