RN130W Service Manual
Contents
1. U OIL LEVELS GEARB FILL VE GEARBOX OIL DRAIN BRAKE ADJUSTMENT N CAUTION DURING REMOVAL SADE AACD Vu SPRING LOADED COVER li I x The brake is adjusted by turning the hex adjuster counter clockwise to increase brake and clockwise to decrease brake The direction of braking for all multiple disc brakes can be changed by removing the cam clutch turning it over and re installing it For detailed service instructions contact your Tulsa Winch distributor or the factory If the input to the winch is accessible and a torque wrench can be adapted to fit it the brake can be set with a torque wrench The RN130W brake is shipped from the factory pre set at 100 Ft Lbs 1 the DISASSEMBLY RUFNEK OIL BRAKE SECTION Remov2. 214023 THRUSTRACE 0 49 W 2 4 4 _ 50 13 O 4 53 4 43751 0 54 5 2123 7 Oo lt Oo o 55 2 44626 sid 56 20 44666 57 20 20558 _ WASHER 58 20 44673 59 1 44621 60 1 448899 RUM 61 6 44888 62 1 44643 0 63 2 43775 2 64 1 44800 0 65 1 44903 sd 66 1 44642 BUSHING 67 3 20522 0 68 1 446 0 69 1 44646 o Y 70 1 44679 71 2 4295 sid 72 2 10381 73 2 939254 _ O 2 4 74 4 75 1 49632 o o o 76 3 9943 77 3 20514 COTTER KEY 1 44916 o o 4 79 44647 CAPSCREW 8 20526 7 81 i 220 _82 1 44037 8 1 2321 7 84 3 43826 KEY 85 1 44669 o _86 1 45520 sg OMIT 8 12 21862 O 2 89 3 20286 90 1 31598
3. SA1 WINCH RUFNEK 130W SERVICE MANUAL GENERAL INFORMATION j sssssssessostesssessseessseessueessesssseessneesseessseessseessueessesssneersneesseessseersneerseesaes 4 INTRODUCTION AND THEORY OF OPERATION ee eee eee 4 ASSEMBLY NUMBER q 4 MODEL CODE annassa 4 MAINTENANCE s 5 OIL LEVELS gt 7 6 BRAKE ADJUSTMENT Se 6 DISASSEMBLY 7 RUFNEK OIL BRAKE 5 7 CLUTCH AND 8 GEARBOX s ee 10 BULL GEAR INSPECTION INSTRUCTIONS Te 12 ASSEMBLY s s S 6 _ 13 GEARBOX 5 _ RUFNEK OIL BRAKE 5 222222222020 17 BILL OF MATERIAL 18 BILL OF MATERIAL CONTINUED 19 TORQUE SPECIFICATIONS CHART U U 20 CLUTCH INSPECTION E 21 ISOMETRIC VIEW 22 SEL 0050 003 DOC REV 2 Apr 2010 WARNING FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJURY OR D
4. O RING pot 1 28673 7 92 1 44057 BRKEPITON o Z o o x 93 1 445 27 94 1 44659 NON ADJUSTABLE BRAKE COVER 19 TORQUE SPECIFICATIONS CHART Grade 5 Grade 5 Grade5 Grade 8 Grade 8 Grade 8 Torque Torque Torque Torque Nominal Size Ft Lbs 1 Ft Lbs 14 20 8 6 5 3 9 7 1 4 28 10 7 6 14 0 8 _ 5 16 18 17 13 10 25 18 15 5 16 24 19 4 11 27 20 16 3 8 16 31 23 19 44 33 26 3 8 4 35 6 21 49 37 30 7 16 14 49 3 30 70 53 2 7 16 20 55 44 33 78 58 47 112 13 76 57 45 106 80 6 1 2 20 85 64 51 10 90 72 9 16 12 109 82 65 153 5 92 _ 9 16 18 22 91 73 172 19 109 5 8 11 150 113 90 212 159 17 5 8 18 170 128 102 240 180 14 3 4 10 266 200 160 376 22 26 3 4 16 297 23 178 420 315 22 7 8 9 430 32 258 606 454 364 7 8 14 474 355 284 668 501 401 1 8 64 483 386 909 682 55 ERS 721 541 433 1019 764 61 1 78 7 794 596 475 1288 96 772 1 1 8 12 890 668 534 1444 1083 866 __7_ 1120 840 672 1817 1363 1090 1 1 2 6 1949 1462 1170 3161 2371 1897 21 072 12 2194 1645 1316 _ 3557 2668 2134 BOLT TORQUE LB FT 12 K TORQUE COEFFICIENT K 0 20 DRY K 0 15 PLATED K 0 12 LUB
5. coupler threads left handed 8 Inspect parts as follows replacing them if necessary A Inspect the carriers 55 for damage Inspect the gear 59 for excessive wear or damage See page 12 for instructions C Inspect the keys 19 amp 83 and bushings 53 for wear damage D Inspect the worm 7 for excessive wear or signs of heat checking or cracks Inspect the bearings 8 amp 93 rings 10 amp 11 and seals 14 amp 30 for excessive wear damage DISASSEMBLY BULL GEAR INSPECTION INSTRUCTIONS w A 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 ASSEMBLY SECTION Press the angular bearings 8 into the bearing carrier 9 as illustrated below then press the bearing carrier and bearings onto the worm 7 and secure with a locknut 13 a washer 12 and another locknut 13 Torque locknut to 150 FT LBS Press the brake side bearing 93 onto the other end of the worm Press a new oil seal 14 into the end cap 15 Install the worm assembly into the gearbox 1 using o ring 10 Secure the end cap 15 with eight capscrews 16 using o ring 11 Torque the capscrews to specification using th
6. flatness must not exceed 1 16 inch across the mounting surface of the winch itself Guards must be placed on all open drives in the case of mechanical winches Insure that all PTO s and drivelines are sized appropriately for the winch manufactures speed and torque specifications N Operator Must read and understand the operating and service manual Both the SERVICE MANUAL and OPERATING AND MAINTENANCE 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 local state and federal regulations for compliance Must insure that the drum clutch is fully engaged before hoisting A visua
7. 7 2 1 and will review winch usage categories on a periodic basis A qualified inspector should perform all maintenance and inspections API RP 2D RECOMMENDED HRS PER MONTH INSPECTION SCHEDULE PRE USE ANNUAL 11 50 PRE USE QUARTERLY PRE USE MONTHLY Oil Maintenance The oil in the gear section and the brake section should be changed every 1000 hrs or 6 months of normal usage e Tulsa Winch recommends that the oil level in the gearbox and brake 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 AMOUNT OIL TYPE GEARBOX SECTION 8 50 QTS SEE CHART BELOW BRAKE SECTION 50 QTS LIGHTWEIGHT NON EP 20W AUTOMATIC TRANSMISSION FLUID OR MOST HYDRAULIC OILS 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 inspection hole Refer to the chart below for the recommended oil type and grade for your application WORM GEAR WINCH REVAILING AMBIENT TEMPERATURE T 40 00 20 10 0 10 20 50 40 50 60 0 80 90 100 110 120 130 5 40 50 FO 0 10 20 50 40 207 All oils must meet MIL PRF2105E standards Substitution from reputable manufacturer is allowed as long as type and grade are maintained 5
8. 75 and Remove the brake band 62 by removing the jam nuts securing the 1 clutch yoke assembly 68 Remove the thrust collar 63 brake band to the air cylinder 69 5 Remove the sliding clutch 65 keys 2 Remove the air cylinders 69 amp 70 84 and the other thrust collar 63 by removing the cotter keys 77 from the clevis pins 76 Continued on page 9 3 Remove the capscrews 4 nuts 6 and washers 5 connecting the end bracket 75 to the frames 2 amp 3 O iy DISASSEMBLY CLUTCH AND DRUM SECTION CONTINUED 6 Remove the brake band assembly B Inspect the bushings 53 amp 66 62 and bracket 71 by removing for excessive wear or damage the capscrews 73 nuts 74 and washers 27 securing them to the Inspect the keys 84 for frame excessive wear or damage 7 Slide the drum 60 off of the output D Inspect the drum clutch 64 and shaft 78 using an overhead hoist Sliding clutch 65 for wear See page 21 this manual for Clutch 8 Inspect parts as follows replacing Inspection them if necessary E Inspect the brake band assembly A Inspect the thrust collars 63 for 62 and verify the lining is at excessive wear or damage least 225 in thick 7 1 DISASSEMBLY GEARBOX SECTION Supporting the end of the output s
9. EATH The safety of the winch operator 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 Additionally 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 www 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 NOTICE Indicates information or a company policy that 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
10. Install the sliding clutch 65 onto the output shaft 78 then slide the clutch over the keys 84 Install the other thrust collar 63 Install the bushing 53 and end cap 82 and then secure it with four capscrews 79 nuts 25 and washers 24 Torque the capscrews to specification using the chart on page 20 6 Install the yoke assembly 68 onto the end bracket 75 then install the end bracket 75 onto the output Shaft 78 being sure to engage the Sliding clutch with the yoke Mount the end bracket to the frame using four capscrews 4 nuts 6 and washers 5 Torque the capscrews to specification using the chart on page 20 Install the brake band 62 onto the drum 60 making sure it is oriented properly for winch arrangement in regard to cable spooling ASSEMBLY CLUTCH POSITION INDICATOR ADJUSTMENT Make sure that the sliding clutch 65 is fully engaged and that the yoke assembly 68 is not binding on the drum clutch The lugs of the yoke MUST be centered in the groove with the clutch fully engaged in order for the clutch position indicator to be properly adjusted See FIG 1 e The switch is a normally open electrical switch that is actuated by disengaging the clutch which closes the circuit e With the clutch fully engaged adjust the switch in until the warning device is activated then back out 1 4 turn to deactivate the warning device e Tighten the jam nut against the clutch brac
11. RAME _4 8 443 x 5 8 44640 _6 8 7 1 485 2 44642 BEARINGS _9 1 44655 000 _10 1 939452 O RING pit 2 32189 RING 22020 12 1 44653 WASHERS sss 2 444 _14 4128565 SEAR 2 _15 1 44635 _16 8 44676 _17 2 16056 sss is 1 20569 SPACER 19 3 44665 pK EY 20 1 44630 COVER C 21 1 2331 BUSHINGS 22 2 13050 0 x 23 8 44674 CAPSCREW sss 24 21120520 25 12 44675 NUT _2 12 43 61 sss 27 4 20518 28 12 44672 NT 29 2 4468 GASKET _3 1 4213 SEAR C 31 1 20278 32 8 30040 0 33 1 44045 S BRAKEHOUSING 00 34 111462 _35 8 930261 36 1 12208 BUSHING 37 1 23390 RETANINGRING o o Oo Y x 38 1 asa po 00660 _39 1 446 40 1 41404 SPRING PLATE 41 3 21684 O 2 1 44151 O RING 43 1 4660 SPRING 44 14 42148 _4 8 32765 SS FRICTIONDDISC 20 ota RAKE RIVER 26980 RETAINING RING 18 BILL OF MATERIAL CONTINUED SEQ QTY P N DESCRIPTION
12. RICATED W PRELOAD TENSION D NOMINAL BOLT SIZE IN ALL TORQUE VALUE TOLERANCES ARE 5 gt g 20 CLUTCH INSPECTION D GOOD CORRECT REVERSE THIS PICTURE ILLUSTRATES DRAFT ANGLE A SLIDING amp DRUM CLUTCH WITH THE PROPER REVERSE DRAFT AND MINIMUM EDGE WEAR MINIMAL EDGE WEAR BAD NOTICE THE REVERSE DRAFT ENSURES THE CLUTCH STAYS ENGAGED DURING NO REVERSE DRAFT ON THE SLIDING OR DRUM CLUTCH WITHOUT THE CORRECT EXCESSIVE EDGE WEAR DRAFT THE CLUTCH ON BOTH THE SLIDING COULD DIS ENGAGE TCH AND DRUM UNPREDICTIBLY wasis CLUTCH REPLACEMENT CRITERIA WARNING IF 1 4 OF THE SURFACE OF THE FACE ON THE SLIDING CLUTCH OR DRUM CLUTCH IS ROUNDED OR HAS NO REVERSE DRAFT ROUNDED FACE THE SLIDING CLUTCH AND OR DRUM CLUTCH MUST BE REPLACED NO REVERSE DRAFT ON THE SLIDING OR DRUM CLUTCH 21 78 ISOMETRIC VIEW OPTIONAL AIK RELEASE NON ADJUSTABLE SPRING APPLIED WITH RELEASE PORT 1200 5251 REQUIRED FOR RELEASE STANDARD OIL BRAKE ADJUSTABLE SPRING APPLIED OD ay ORS 0 22
13. e chart on page 20 Install the key 83 into the worm 7 Install the keys 19 into the output Shaft 78 and then slide the carrier the 55 over the keys Install WASHER 1 LOCKNUTS 13 Spacer 18 using two pins 17 Slide the gear 59 and the other carrier 55 onto the shaft and secure with twenty capscrews 56 nuts 58 and washers 57 Torque the capscrews to specification using the chart on page 20 Slide two bushings 53 onto both ends of the shaft Carefully lower the output shaft assembly into the housing 1 Install both gaskets 29 onto the housing 1 Attach the cover 20 to the housing using capscrews 23 amp 26 nuts 25 amp 28 and washers 24 amp 88 Torque the capscrews to specification using the chart on page 20 ASSEMBLY RUFNEK OIL BRAKE SECTION Press the oil seal 30 into the brake housing 33 Attach the brake housing to the gearbox with eight capscrews 32 using o ring 11 Be sure to torque the capscrews to specification using the chart on page 20 Install the key 52 into the worm Reassemble the clutch assembly components A Install the thrust race 48 and bushing 49 onto the coupler 51 B Install the cam clutch 50 and driver 46 onto the coup
14. e the bottom drain plug 41 to drain the oil from the brake Loosen the spring tension inside the brake by rotating the adjusting nut 39 clockwise until it stops 4 CAUTION Extreme care should be taken when removing the brake cover The cover is spring loaded against the cover bolts Evenly remove the capscrews 35 from the brake cover 34 spring 43 and retaining ring 47 then remove the clutch assembly components 46 48 49 and 50 along with friction discs 45 and stator plates 44 Be sure to examine and note the direction of lockup on the cam clutch 50 for reinstallation s 5 If necessary remove the coupler 51 by removing the retaining rings 47 amp 90 and threading the coupler out of the worm NOTICE The coupler threads are left handed Inspect parts as follows replace if necessary A Inspect the friction discs 44 for uneven excessive wear Friction discs should measure no less than 055 in thick B Inspect the stator plates 45 for warpage or excessive wear Inspect the spring 43 for damage or discoloration D Cam clutch 50 should be free of debris and have all cams intact Check the driver 46 and coupler 51 for signs of pitting spalling or excessive wear Check the seal 30 for damage jj gt 5 lt 5 lt gt lt 5 4 Remove the end bracket
15. haft 78 with a hoist remove the housing cover 20 by removing capscrews 23 amp 26 nuts 25 amp 28 and washers 24 amp 88 Use the hoist to lift the output shaft 78 bushings 53 and gear assembled items 17 18 19 53 55 56 57 58 and 59 out of the housing 1 10 Remove the bushing 53 from the output shaft 78 Remove the gear 59 from the carriers 55 by removing the twenty capscrews 56 nuts 58 and washers 57 then pull the carrier 55 off of the shaft 78 Finally remove the spacer 18 carrier 55 and keys 19 Continued on page 11 Remove the DISASSEMBLY GEARBOX SECTION CONTINUED NOTICE If the brake has not been removed see brake disassembly on pages 10 13 of this manual worm assembly assembled items 7 8 9 10 12 13 51 83 and 90 from the housing by removing the end cap 15 From the brake end push the worm assembly out of the housing 90 being careful not to damage the oil seal 30 in the brake housing Disassemble the worm by removing the bearing locknut 13 washer 12 and then other locknut Press the worm out of the bearings 8 amp 93 Next press the two angular contact bearings out of the bearing carrier 9 If the coupler 51 shows signs of wear or damage remove the coupler and retaining ring 90 then replace it with a new one Use Loctite 277 on coupler threads when replacing NOTICE The
16. ket to secure the adjustment e Test the switch by fully engaging then disengaging the clutch The warning device should activate while disengaging the clutch pivoting no more than 3 FIG 1 FIG 2 16 TROUBLESHOOTING FAILURE PROBABLE CAUSE Clutch won t engage a Clutch jaws aren t aligned Align the jaws by rotating drum b Damaged yoke linkage airline cylinder Replace the damaged components c Lack of draft angle or excessive wear on clutch jaws Replace the clutch Oil leaks from housing a O ring is damaged Replace the o ring Load drifts a The brake is out of adjustment or worn Adjust brake until load doesn t drift If adjustment doesn t correct problem service brake and worm to replace worn components b Load exceeds winch rating Reduce work load Cable drum won t free spool a Winch not mounted squarely Check mounting and confirm that the winch is mounted on a level surface b Clutch not disengaged Disengage the clutch Drum bushings are running Grease winch at all grease points zerk fittings Winch won t pick up heavy loads a Too much cable on the drum Use the Snatch block or remove some cable from the drum b Winch not broke in See Break in section of this manual c Load exceeds winch rating Reduce work load 17 BILL OF MATERIAL SEQ P N 1 1 44624 2 1 44628 8 1 442 W LEFT F
17. l 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 The drum brake is not a load holding device It is designed to prevent over spooling of the drum causing the cable to bird nest on the drum Inspect the brake band for worn lining and the actuation method Must inspect the load control brake This winch is equipped with a form of dynamic braking The worm brake is adjustable for pay out load control Before a load is handled the load should be pulled tight and stopped 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 e minimum of five wraps of tightly wound cable must remain on the drum 3 GENERAL INFORMATION INTRODUCTION AND THEORY OF OPERATION The Tulsa worm gear winch is operated by turning the input of the worm using a PTO driven sprocket and chain This winch utilizes the adjustable spring applied multiple disc oil brake that activates only during pay out to provide maximum efficiency during pay in An optional
18. ler being sure the clutch is oriented correctly as defined in Brake Disassembly C Install the other bushing 49 and thrust race 48 along with the retaining ring 47 onto the coupler Install the clutch assembly onto the 14 Install FRICTION Install the retaining ring 37 on the worm 7 Install the stator plates 44 and friction discs 45 in the correct layout as shown below Install the spring 43 the adjusting components items 38 39 and 40 into the brake cover 34 and attach it to the brake housing 33 with eight evenly installed capscrews 35 using o ring 42 Torque the capscrews to specification using the chart on page 20 Install the drain plug 41 into the bottom of the brake cover 34 Fill gearbox and brake with proper oil Refer to winch maintenance section on page 5 of this manual for oil type and amounts 10 Adjust the brake using the procedure on page 6 of this manual STATOR DISC PLATE ASSEMBLY CLUTCH AND DRUM SECTION Install bushings 53 into the drum 60 Slide the drum onto the output Shaft 78 Slide the thrust collar 63 onto the output shaft 78 Install the keys 84 into the output shaft
19. non adjustable air released brake is also available 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 002 In 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 82128 002 MODEL CODE RN130 WMRFOAX Motor Type 1 Single Speed Gear Motor 2 Two Speed Gear Motor Drive T 6 y 3 Single Speed Geroler Motor ee 4 Two Speed Geroler Motor M Mechanical heed Gearbox Position L Left X No Motor R Right Clutch Device viewed from rear of truck M Mechanical Input Shaft Location A Air Cable Spooling O Over Drum U Under Drum viewed from rear of truck X Does not apply viewed from rear of truck Tulsa Winch worm gear driven winches require regular maintenance to ensure safe and reliable operation Regular oil changes with the correct oil for the ambient temperature conditions and an annual inspection of the wear components is strongly recommended Maintenance Scheduling The owner is to ensure proper inspection intervals in compliance with the API RP 2D Section 4 ANSI B30 5 5 2 3 or ANSI B30 7
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