RN10W Service Manual
Contents
1. 35 1 32566 O RING 36 zi OMIT 37 OMIT 38 2 40410 CAPSCREW 39 2 20270 CAPSCREW 40 2 20271 NUT 41 2 20526 LOCKWASHER 42 1 41244 C T O HANDLE 43 1 41250 HANDLE GRIP 44 1 21128 GREASE ZERK 45 1 40069 BRAKE HOUSING 46 1 40617 BRAKE HUB 47 2 40075 FRICTION DISC 48 2 40076 STATOR PLATE 49 1 40113 CLUTCH CAM 50 1 40077 SPRING 51 1 40078 THRUST WASHER 52 1 40775 SET SCREW 53 1 40774 LOCKNUT 54 1 29044 WASHER 55 1 40599 BRAKE SPACER 56 2 40546 CAPSCREW 57 OMIT 58 1 40082 END CAP 59 1 20232 OIL SEAL 60 1 20105 KEY 61 1 20092 WASHER 62 1 20278 CAPSCREW 63 1 44024 RUFNEK PLATE 15 us Tulsa Winch TORQUE SPECIFICATIONS CHART Dry Plated Lubricated Dry Plated Lubricated SAE SAE SAE SAE SAE SAE Grade 5 Grade 5 Grade 5 Grade 8 Grade 8 Grade 8 1 4 20 8 6 5 12 9 7 1 4 28 10 7 6 14 10 8 5 16 18 17 13 10 25 18 15 5 16 24 19 14 11 27 20 16 3 8 16 31 23 19 44 33 26 3 8 24 35 26 21 49 37 30 7 16 14 49 37 30 70 53 42 7 16 20 55 41 33 78 58 47 1 2 13 76 57 45 106 80 64 1 2 20 85 64 51 120 90 72 9 16 12 109 82 65 153 115 92 9 16 18 122 91 73 172 129 103 5 8 11 150 113 90 212 159 127 5 8 18 170 128 102 240 180 144 3 4 10 266 200 160 376 22. and thrust plate 51 for warpage excessive wear or other damage C Examine the spring 50 for any discoloration D The cam clutch 49 should be free of any debris and have all rollers intact If cam clutch needs to be replaced a new cam clutch should be carefully pressed into the brake hub 46 CLUTCH AND DRUM DISASSEMBLY 1 Remove the four capscrews 12 nuts 15 and washers 16 attaching the end bracket 1 to the frames 13 Remove the end bracket 1 lever assembly 17 sliding clutch 24 and keys 14 from the output shaft 3 Remove the thrust washer 27 With the support of a hoist remove the drum 2 Inspect parts as follows replace if necessary A Inspect the bushing 19 in the end bracket 1 for excessive wear B Inspect the lever assembly 17 sliding clutch 24 keys 14 and thrust washer 27 for excessive wear See page 14 for clutch inspection C Inspect the bores of the drum 2 for excessive wear or damage D Check the drag brake 8 for excessive wear E Inspect the oil seal 25 for any leaks GEARBOX DISASSEMBLY 1 Remove the brake from the gearbox See brake disassembly section of this manual Remove either the motor 23 or the end cap 58 depending on type of drive by removing two capscrews 38 Remove the snap ring 32 from the brake end of the worm From the brake end push the worm while rot
3. 4 engaging the gear 29 as you push it through Once the worm 30 is in place install the other bearing 33 and retaining ring 32 onto the worm 30 If your winch uses mechanical input install a new oil seal 59 into the end cap 58 Install the end cap with two capscrews 38 If your winch uses a hydraulic motor Install the motor 23 and o ring 35 Fill to the proper oil level with the recommended lubricant See maintenance section of this manual on page 6 BRAKE ASSEMBLY 1 2 Insert the following parts into the brake housing 45 in this order Thrust washer 51 Spring 50 Stator plate 48 Friction disc 47 Cam clutch brake hub assembly 46 49 Friction disc 47 Stator plate 48 Brake spacer 55 Gasket 21 Install the brake assembly onto the gearbox 4 with two capscrews 56 3 Tighten the brake adjustment screw 52 until tension from the spring 50 is felt See brake adjusting section of this manual NOTICE Factory preset is 8 ft Ibs worm input Fill to the proper oil level with the recommended lubricant See maintenance section of this manual on page 6 CLUTCH AND DRUM ASSEMBLY 1 If necessary replace the oil seal 25 in the gearbox 4 Place some grease into the pockets located on the back of the gearbox 4 and install the springs 9 and drag brakes 8 The grease should hold them in place Grease the inside of the drum bore an
4. AND THEORY OF OPERATION The Rufnek series worm gear winch is operated by turning the input of the worm using a hydraulic motor or PTO driven sprocket and chain The winch utilizes an adjustable brake that activates only during pay out to provide maximum efficiency during pay in The torque is transferred from the gearbox through the drum shaft which is keyed to a mechanically actuated sliding clutch that when engaged transfers the torque to the drum ASSEMBLY NUMBER EXPLANATION This manual is for design series 001 the case of a major design change implementation a new design series designation number will be issued for the winch A new manual will also be created for that specific design series DESIGN ASSEMBLY SERIES 81276 001 WINCH BREAK IN Winches like any other kind of machinery require a break in to perform well and to maximize their life The following guidelines should be used in the break in of Tulsa Winches Use extreme care when first spooling cable onto the winch DO NOT run the winch at high speeds when performing this operation Make sure that the cable is payed out in a straight line to prevent kinks and SLOWLY pay in the winch to install the cable DO NOT exceed one half rated load or one half rated line speed for the first thirty minutes of operation This will insure that the worm and gear have an opportunity to wear in properly Periodically check the gearbox for temperature rises a
5. remove some cable from the drum x Winch won t pick up heavy loads a b System pressure too low Increase the hydraulic system pressure Winch not broke in Run winch at half of rated load for several pulls RUFNEK 10 BILL OF MATERIAL 81276001 BOM SEPTEMBER 2005 ITEM QTY P N DESCRIPTION 1 1 41207 END BRACKET 2 1 41190 DRUM 3 1 41193 OUTPUT SHAFT 4 1 41188 HOUSING 5 1 12208 BUSHING 6a 1 44046 RUFNEK 10W COVER 6b 1 41192 MODEL 1138 COVER 7 1 23582 SET SCREW 8 3 25692 DRAG BRAKE 9 3 25774 SPRING 10 1 40547 O RING 11 4 40407 CAPSCREW 12 8 10381 CAPSCREW 13 2 41197 FRAME 14 2 25762 KEY 15 8 20521 NUT 16 8 20518 LOCKWASHER 17 1 4069 LEVER ASSEMBLY 17 1 1 41185 YOKE 17 2 1 20296 PIN 17 3 1 20299 SPRING 17 4 1 20304 PIN 17 5 2 33786 FLAT WASHER 17 6 1 20723 BRACKET 17 7 1 20116 PIN 17 8 2 24724 RETAINING RING 18 OMIT 19 1 41238 BUSHING 20 OMIT 21 2 40147 GASKET 22 1 13050 BREATHER 23 1 40121 HYDRAULIC MOTOR 24 1 20712 CLUTCH 25 1 11637 OIL SEAL 26 2 41196 BUSHING 27 3 40510 THRUST WASHER 28 2 40518 KEY 29 1 41198 GEAR 30a 1 40598 WORM HYDRAULICALLY DRIVEN 30b 1 40635 WORM MECHANICALLY DRIVEN 31 OMIT 32 2 40396 RETAINING RING 33 2 40395 BEARING 34 2 32220 PLUG 14 RUFNEK 10 BILL OF MATERIAL CONTINUED
6. 82 226 3 4 16 297 223 178 420 315 252 7 8 9 430 322 258 606 454 364 7 8 14 474 355 284 668 501 401 1 8 644 483 386 909 682 545 1 14 721 541 433 1019 764 611 1 1 8 7 794 596 475 1288 966 772 1 1 8 12 890 668 534 1444 1083 866 1 1 4 7 1120 840 672 1817 1363 1090 1 1 4 12 1241 930 745 2012 1509 1207 T BOLT TORQUE LB FT K TORQUE COEFFICIENT K 0 20 DRY W PRELOAD TENSION D NOMINAL BOLT SIZE IN ALL TORQUE VALUE TOLERANCES ARE 5 T KWD 12 K 0 15 PLATED K 0 12 LUBRICATED THIS PICTURE ILLUSTRATES A SLIDING amp DRUM CLUTCH WITH THE PROPER REVERSE DRAFT AND MINIMUM EDGE WEAR CORRECT REVERSE DRAFT ANGLE MINIMAL EDGE WEAR BAD EXCESSIVE EDGE WEAR ON BOTH THE SLIDING A WARNING CLUTCH AND DRUM THE REVERSE DRAFT ENSURES THE CLUTCH STAYS ENGAGED DURING PAY IN WITHOUT THE CORRECT AO NE NO REVERSE DRAFT COULD DIS ENGAGE ON THE SLIDING OR UNPREDICTIBLY DRUM CLUTCH CLUTCH REPLACEMENT CRITERIA REPLACEMENT CRITERIA NOTICE IF 1 4 OF THE SURFACE OF THE FACE ON THE SLIDING CLUTCH OR DRUM CLUTCH IS ROUNDED OR HAS NO REVERSE DRAF THE SLIDING CLUTCH AND OR DRUM CLUTCH MUST BE REPLACED NO REVERSE DRAFT ON 17 ROUNDED THE SLIDING OR DRUM CLUTCH RUFNEK 10 ISOMETRIC DRA
7. WING IL LEVEL HOLE J 18
8. ance The oil should be changed every 1000 hrs or 6 months of normal usage e Tulsa Winch recommends that the oil level in the gearbox be checked and adjusted as part of the pre use inspection If the oil level drops frequently or oil leakage is detected during an inspection maintenance should be performed to correct any problems OIL CAPACITY 75 QTS e Gearbox oil level inspection is achieved by removing the oil level inspection plug and visually inspecting the oil level Minimum oil level is to the bottom of the threads of the oil level hole See page 7 for oil level hole location Refer to the chart below for the recommended oil type and grade for your application WORM GEAR WINCH PREVAILING AMBIENT TEMPERATURE t 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 F 222020200 SAE 140W AGMA MOBIL SHC 626 5 MOBILUBE HD80W140 C 40 30 20 10 0 10 20 30 40 All oils must meet MIL PRF2105E standards Substitution from a reputable manufacturer is allowed as long as type and grade are maintained OIL LEVEL GEARBOX FILL VENT GEARBOX OIL DRAIN MAINTENANCE CONTINUED BRAKE ADJUSTMENT This brake uses a one way cam clutch 49 a
9. ating it in order to remove the worm from the gearbox Remove the cover 6 from the gearbox by removing the four capscrews 11 Remove the thrust washer 27 and gear 29 NOTICE If the bushing in the gearbox needs to be replaced a complete teardown is necessary Inspect parts as follows replace if necessary A Inspect the worm 30 for excessive wear signs of heat checking or cracks B Inspect the bearings 33 for excessive wear or damage C Inspect the thrust washers 27 bushing 26 and gear 29 for excessive wear D Inspect the keys 28 and output shaft 3 for damage GEAR INSPECTION INSTRUCTIONS Check gear wear by removing the cover and visually inspecting the bronze gear If the gear is worn such that there is no visible land on the throat of the gear between the gear flanks as shown in picture above the gear should be replaced 10 ASSEMBLY GEARBOX ASSEMBLY Install the bushings 26 into the gearbox 4 and cover 6 Install the thrust washer 27 and keys 28 onto the output shaft 3 Slide the gear 29 over the keys 28 and against the thrust washer 27 Slide the other thrust washer 27 onto the output shaft 3 Install the cover 6 using the four capscrews 11 being careful not to damage the o ring 10 Install one bearing 33 and retaining ring 32 onto the end of the worm 80 then install the worm 30 into the gearbox
10. d the output shaft Install the drum 2 and thrust washer 27 onto the output shaft 3 4 Install the sliding clutch 24 lever 17 and end bracket 1 Attach the end bracket 1 to the frames using four capscrews 12 nuts 15 and washers 16 Install the plug 34 into the bottom of the gearbox 4 Fill to the proper oil level with the recommended lubricant see page 6 of this manual TROUBLESHOOTING FAILURE PROBABLE CAUSE Clutch handle won t latch a Clutch jaws aren t aligned Align the jaws by rotating drum E Damaged yoke or linkage Replace damaged parts Seal damaged or worn Replace the seal s Oil leaks from housing a gZ Too much gearbox oil Drain excess oil Oil cooled brake out of adjustment or worn Adjust brake until load doesn t drift Replace the parts as required Low flow rate Check the flow rate and increase if necessary Load drifts down a Winch runs too slow a Hydraulic motor worn out Replace the motor Winch not mounted squarely Check mounting and confirm that the winch is mounted on a flat surface Cable drum won t free spool a Clutch not disengaged Disengage the clutch Cable birdnests when clutch isla Drag brakes are worn Replace the disengaged drag brakes Hydraulic fluid leaks from the gearbox Damaged motor shaft seal Replace the seal Too much cable on the drum Use the snatch block or
11. llowing free spooling in the in haul direction and engages in the payout direction To increase the brake torque follow the steps listed below 1 2 Loosen the locknut 53 Increase the brake torque by turning the adjusting screw 52 clockwise Tighten the locknut 53 after the brake adjustments are completed The brake should be adjusted to hold no more than the winch rating If the brake does not respond to adjustment the brake must be disassembled and inspected per brake disassembly section of this manual amp CAUTION Excessive brake torque can cause over heating and premature wear DISASSEMBLY BRAKE DISASSEMBLY Remove the bottom plug 34 to drain the oil Loosen the locknut 53 and brake adjusting screw 52 to reduce spring force on brake housing 45 Remove the capscrews 56 from the brake housing 45 Remove the brake housing 45 thrust washer 51 and spring 50 from the gearbox Remove the stator plates 48 friction discs 47 brake hub 46 spacer 55 and cam clutch 49 from the worm 30 NOTICE Make sure to note the direction that the cam clutch and brake hub are installed They must be re installed the same way 6 Inspect parts as follows replace if necessary A Inspect the friction discs 47 for excessive wear Friction discs should measure no less than 065 in thick B Inspect the flat surfaces of the brake hub 46 stator plates 48
12. local state and federal regulations for compliance Must insure that the drum clutch is fully engaged before hoisting A visual inspection of the drum clutch engagement is required before each winching operation Must rig all loads secure before winching Pull the load line taut and inspect the condition of load for stability Must inspect the drum brake if equipped The drum brake is not a load holding device it is design to prevent over spooling of the drum and causing bird nesting of the cable on the drum Inspect the brake for wear of the lining and the actuation method Must inspect the load control brake These winches can be equipped with two 2 forms of dynamic braking The worm brake is one method and is adjustable for pay out load control Before a load is handled the load should be pulled tight and stopped to check this brake The second method is a hydraulic lowering control that is not field adjustable The same method should be used to check this brake Operation e All winch controls must be well marked for function to avoid confusion e Insure that the PTO is disengaged when the winch is not in use e All winch controls must be located to provide the operator with a clear view of the load e The clutch must be inspected daily for proper operation e The winch cable should be inspected daily for serviceability minimum of five wraps of tightly wound cable must remain on the drum GENERAL INFORMATION INTRODUCTION
13. ms Tulsa Winch RUFNEK 10 AND MODEL 1138 SERVICE MANUAL INTRODUCTION AND THEORY OF OPERATION 2 4 ASSEMBLY NUMBER EXPLANATION 2 4 WINCH BREAK IN 2 4 MODEL CODE nin deii cu lu vai dic S dni C E a c i i 5 MAINTENANGCE a sasa usss icr i in aandaa 6 LEVELS ce ee 7 BRAKE ADJUSTMENT 0808080008888 8 DISASSEMBLY PER 8 BRAKE DISASSEMBLY 8 CLUTCH AND DRUM DISASSEMIBIE EN 9 GEARBOX DISASSEMBLY 9 GEAR INSPECTION _ 10 ee 11 GEARBOXASSEMBNE __ 11 C MM 11 CHUTCHANDDRUMASSEME Mu 12 13 RUFNEK 10 sere II 14 TORQUE SPECIFICATIONS CHART ns 16 CLUTCH INSPECTION 17 RUFNEK 10 ISOMETRIC DRAWING ee 18 SEL 0043 001 DOC REV 0 WARNING FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH The safety of the winch o
14. nd allow the winch to cool down between pulls Worm gear winches are designed and intended for intermittent duty application only using them in extremely long pulls may generate excessive heat and shorten the life of the winch MODEL CODE RN10 WHRF1MO Gear Type Cable Spooling W Worm O Over Drum P Planetary U Under Drum Drive Type viewed from rear of truck Clutch Device M Mechanical i x M Mechanical Gearbox Position A Air L Left Motor Type of truck R Right viewed from rear 1 Single Speed Gear Motor Input Shaft Location 2 Two Speed Gear Motor F Front 3 Single Speed Geroler Motor R Rear 4 Two Speed Geroler Motor X Does not apply 5 Piston viewed from rear of truck 6 Vane X No Motor Tulsa Rufnek series worm gear winches require regular maintenance to ensure safe and reliable operation Routine oil changes with the correct oil for the ambient temperature conditions and a regular inspection of the wear components is strongly recommended Maintenance Scheduling The owner is to insure proper inspection intervals in compliance with the API RP 2D Section 4 ANSI B30 5 5 2 3 or ANSI B30 7 7 2 1 and will review winch usage categories on a periodic basis A qualified inspector should perform all maintenance and inspections USE API RP 2D RECOMMENDED HRS PER MONTH INSPECTION SCHEDULE 0 10 PRE USE ANNUAL 11 50 PRE USE QUARTERLY 51 PRE USE MONTHLY Oil Mainten
15. perator and ground personnel should always be of great concern and all necessary precautions to insure their safety must be taken The primary mover and the winch must be operated with care and concern for the equipment and the environment and with a thorough knowledge of the equipment and its performance capabilities must be understood These general safety guidelines are offered however local rules and regulations or national standards may also apply Recommended references are but not limited to ANSI B30 OSHA 1910 AWS D 14 3 and SAE J706 Additional information can be found at http Awww team twg com TulsaWinch Indicates an imminently hazardous situation A DANGER which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which A WARNING if not avoided could result in death or serious injury Indicates a potentially hazardous situation which A CAUTION if not avoided may result in minor or moderate injury or property damage Indicates information or a company policy that NOTICE relates directly or indirectly to the safety of personnel or protection of property Mounting Winch mounting must be secure and able to withstand the applied loads The stability of the mounting system must be approved by a qualified person All welding should also be done by a qualified person Winch mount must be flat so as not to induce binding The flatness must not exceed 1 16 inch ac
16. ross the mounting surface of the winch itself Guards must be placed on all open drives in the case of mechanical winches Insure that all hydraulic hoses valves and fittings are rated to winch manufacturer s operating pressures Relief valves should be set to winch manufacturer s specifications Insure that all PTO s and drivelines are sized appropriately for the winch manufactures speed and torque specifications Operator Must read and understand the operating and service manual Both the SERVICE MANUAL and OPERATING MANUAL are available online at http www team twg com TulsaWinch Must never lift or move people with this winch This winch is not designed or intended for any use that involves moving people Must stay clear of the load at all times Ground personnel should remain a safe distance from the load and winch cable at least 1 1 2 times the length of cable measured from the winch to the load Must stay clear of the cable at all times A broken cable can cause serious injury or death Must avoid shock loads Shock loads can impose a strain on the winch that can be many times the design rating Must be aware of the fleet angle of the winch All loads should only be pulled with the load line perpendicular to the drum shaft this is to avoid excessive stresses on the winch and will help prevent the cable from building on one side of the drum flange Must wear personnel protective equipment PPE if required Check the
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