rn100p service manual
Contents
1. S KN OL LEVEL DIA E 6 60 x DN IT HOLES RT Z z L N i s SP lje al a m 82 a 63 Fi g A 28 ER 30 a gt Es 25 i gt 0 GB SE Y 2 AN PG METERING NET 4 26 HOLE NY H g 78 u 80 26 og SER A 88 ee B BRAKE SECTION DISASSEMBLY 1 6 0 Evenly remove the four cap screws 60 that hold the brake cover 18 in place Spring pressure will raise the cover up as the cap screws 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 1 240 inches with no force on them Remove the piston 54 by installing two pieces of 3 8 16NC all thread into the two 4 CAUTION If a complete tear down is not necessary make sure the input shaft 21 does not move during removal of the drum to 104 will fall into the gear set ultimately causing failure to the gear section of the winch The gear cover 3 will have to be removed to re position the spacer on the input shaft 62 If the shaft is allowed move the input spacer 16 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 shop air to slowly pressurize the brake port to remove the piston from the brake housing 16 Inspect o rings 55 57 and back up rings 56 58 on the pi2. i OMIT 102 3 OMIT 103 4 43078 SPACER 104 1 31543 O RING 105 E OMIT 106 4 29614 CAPSCREW 107 1 939243 CLEVIS PIN 108 3 20514 COTTER PIN 109 OMIT 110 1 43877 CLUTCH BRACKET 111 E i OMIT 112 z E OMIT 113 3 994188 SHIM 114 2 33324 SHIM 26 an Wi Mimi G u Tulsa nen 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 sele a IE NN 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 10 266 200 160 376 282 226 3 4 16 297 223 178 420 315 252 7 8 9 430 322 258 606 454 364 718 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
3. making sure it is against the thrust washer Put the outer thrust washer 34 in place and slide the input shaft 21 all the way through the output shaft 20 Let the input shaft protrude 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 Put the cover 3 on and secure it with six capscrews 30 being careful not to damage the o ring 33 Install the Intelliguard sensor 21 into the cover again making sure not to damage the o ring 104 add loctite and secure it with three capscrews 6 NOTICE Make sure the input shaft engages the gear in the Intelliguard correctly L DRUM SECTION ASSEMBLY 51 97 103 After inspecting and replacing the necessary parts such as the drum bushings 19 install the drum 11 onto the output shaft 20 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 along with the bracket 90 capscrews 91 nuts 85 and washers 86 NOTICE You may need to lower the drum to align the holes in the brake band with the holes in the frame Install the brake band air cylinder 76 making sure the rod of the air cylinder is going through the bracket on the brake band 77 Secure it to the bracket 90 with the 107 clevis pin and cotter key 108 19 Tighten the adjusting nut on th
4. 5 M BRAKE SECTION ASSEMBLY Install the driver clutch assembly onto the input shaft 21 Install the stator plates 52 and friction discs 53 starting with a stator plate and alternating between friction discs and stator plates until seven stator plates and six friction discs are used NOTICE Dip friction discs in lightweight Non EP oil before installation Install the piston 54 into the brake housing 16 and gently tap it down until it is seated making sure not to damage the o rings 55 57 or back up rings 56 58 Install the springs 59 into the spring pockets If working in a horizontal position coat the bottom of each spring with chassis lube to keep it in position Install the cover 16 onto the brake housing 16 using four cap screws 60 Draw the cover down evenly alternating between opposite hex bolts Make sure that the cover is aligned properly with the brake housing to orient the motor correctly Check the brake release with a portable hydraulic pump Full release should be obtained at 340psi plus or minus 20psi Also check the brake for proper operation by applying 107psi to the brake port and adapting a torgue wrench to the input shaft The torgue in the payout should be 142 to 162 ft lbs BRAKE PORT N MOTOR ASSEMBLY 1 Install the o ring 62 onto the motor 63 4 and install the motor using four capscrews 30 Tighten the capscrews to the proper torque specifica
5. 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 are equipped with two 2 forms of dynamic braking The spring applied hydraulically released multi disc oil brake is one method 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 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 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 A minimum of five wraps of tightly wound cable must remain on the drum MAINTENANCE Tulsa Rufnek series planetary winches like any other piece of machinery need to be periodically serviced and wel
6. on the input shaft make sure the If the shaft is allowed the input spacer 51 97 403 o 108 16 11 cylinder You can now remove the brake band assembly 77 Note which frame the mounting bolts are on for re assembly Inspect and replace if needed 3 Remove the outer thrust collar 48 by loosening three set screws 89 4 Remove the yoke 17 sliding clutch 13 and coupler 12 Remove the three keys 47 and the inner thrust collar 46 Remove the drum using a hoist Inspect the bushings 9 in both ends of the drum NOTICE You should also inspect the bushing and seal 40 41 that are located in the end of the brake housing 5 lf necessary 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 See torque specifications chart on page 28 of this manual 92 CLUTCH INSPECTION GOOD CORRECT REVERSE DRAFT ANGLE THIS PICTURE ILLUSTRATES A SLIDING amp DRUM CLUTCH WITH THE PROPER REVERSE DRAFT AND MINIMUM EDGE WEAR MINIMAL EDGE WEAR BAD NOTICE NO REVERSE DRAFT THE REVERSE DRAFT ON THE SLIDING OR ENSURES THE CLUTCH DRUM CLUTCH STAYS ENGAGED DURING PAY IN WITHOUT THE CORRECT DRAFT THE CLUTCH COULD DIS ENGAGE UNPREDICTIBLY EXCESSIVE EDGE WEAR ON BOTH THE SLIDING CLUTCH AND DRUM CLUTCH REPLACEMENT CRITERIA ROUNDED F
7. 2012 1509 1207 T z BOLT TORQUE LB FT T KWD 12 K TORQUE COEFFICIENT K 0 20 DRY W PRELOAD TENSION D NOMINAL BOLT SIZE IN K 0 15 PLATED K 0 12 LUBRICATED ALL TORQUE VALUE TOLERANCES ARE 5 28 RUFNEK 100 ISOMETRIC DRAWING 2 E iat 4 23 6 gt VIET N 23 4 23 7 23 2 4A CAUTION DO NOT USE MAGNETS ON OR AROUND WINCH 29
8. ACE WARNING IF 1 4 OF THE SURFACE OF THE FACE ON THE SLIDING CLUTCH OR DRUM CLUTCH IS ROUNDED OR HAS NO REVERSE DRAFT THE SLIDING CLUTCH AND OR DRUM CLUTCH MUST NO REVERSE DRAFT BE REPLACED ON THE SLIDING OR DRUM CLUTCH 10 D GEAR SECTION DISASSEMBLY 1 Drain the oil by removing the plug 86 located on the bottom of the end cover 3 To disassemble the gear section remove the Intelliguard sensor 21 from the end cover 3 by removing three capscrews 6 Inspect the gear teeth on the Intelliguard 21 for wear The Intelliguard system is not serivceable in the field Return to an authorized dealer for service Remove the end cover 3 by removing the six capscrews 30 Inspect the o rings 33 8 104 for wear and replace if necessary Remove the input gear set 22 and thrust washers 34 8 37 Inspect and replace if necessary 20 Remove secondary gear set 23 and sun gear 7 Inspect and replace if necessary Remove the secondary gear housing 9 by removing eight cap screws 35 Inspect the o ring 36 and replace if necessary 4 WARNING The housing is very heavy Use caution when removing it Remove the sun gear 8 Rotate the thrust plate 24 7 into alignment with the snap ring 24 8 Remove the snap ring from the groove on the output shaft 20 Remove the output gear set 24 and thrust washer 38 Inspect and replace if necessary E INPUT P
9. CH YOKE 18 1 43419 BRAKE COVER 19 2 42868 BUSHING 20 1 42869 OUTPUT SHAFT 21 1 4480 INTELLIGUARD SYSTEM 22 1 4250 INPUT GEAR SET 22 1 1 43183 INPUT CARRIER 22 2 3 42877 PLANET GEAR 22 3 3 30484 NEEDLE BEARING 22 4 3 41715 RETAINING RING 22 5 3 41760 PLANET PIN 22 6 6 27221 THRUST RACE 22 7 1 42954 THRUST PLATE 23 1 4229 SECONDARY GEAR SET 23 1 1 42926 SECONDARY CARRIER 23 2 3 42876 SECONDARY PLANET GEAR 23 3 6 41717 BEARING 23 4 3 41716 RETAINING RING 23 5 3 42951 PLANET PIN 23 6 6 939249 THRUST RACE 23 7 1 42957 THRUST PLATE 24 1 4230 OUTPUT GEAR SET 24 1 1 42927 OUTPUT CARRIER 24 2 3 42878 OUTPUT PLANET GEAR 24 3 9 939247 NEEDLE BEARING 24 4 3 41901 RETAINING RING 24 5 3 42952 PLANET PIN 24 6 6 27219 THRUST RACE 24 RODE 100 BILL OF MATERIAL conTINUED 24 7 42957 THRUST PLATE 24 8 i 43699 RETAINING RING 25 4 43372 CAPSCREW 26 2 32182 O RING 27 OMIT 28 1 41867 COUNTERBALANCE VALVE 29 1 32411 HEX PLUG 30 12 20524 CAPSCREW 31 2 41719 O RING PLUG 32 1 42137 CAPLUG 33 1 28947 O RING 34 2 42934 THRUST WASHER 35 8 28212 CAPSCREW 36 1 32368 O RING 37 1 42935 THRUST WASHER 38 1 42936 THRUST WASHER 39 1 42978 SPECIAL O RING PLUG 40 2 42930 BUSHING 41 2 44690 OIL SEAL 42 OMIT 43 1 42937 U BOLT 44 2 21214 NUT 45 6 21644 CAPSCREW 46 1 42938 THRUST COL
10. DESIGN SERIES 004 AR RUFNEK 100 RUFNEK SERVICE MANUAL win Intelliguard GA Tulsa Winch INTRODUCTION AND THEORY OF OPERATION 2 12222 n arssreezasean nena nena az naa az nanasa nan nnnnaznanaa 2 ASSEMBLY NUMBER EXPLANATION 2 s sssssssrsssusss2s gt crono rr rr 2 WINCH MODEL CODE SN A n0r arv ons rara 2 MAINTENANCE AM retener 00000000 O ecc 5 GENERAL DISASSEMBEYGGSSSTA 202222111212 ZN een Era aura sanne ne nn ner 6 A MOTOR D SSE NTG ar 6 B BRAKE SEGTIONIDISASSEMBLY lt gt EE l 7 C AUN SECTION DISASSEMBLY Er le NR 9 D EEARISECTION BDIS SSEMBLY RON ANN v 11 E MOQUMP LANE T SETDISASSEMBIY O A E 12 F SECONDARY PLANET SET DISASSEMBLY SEE smem Met 13 GAOUTEON PLANET SEMDISASSEMBL a E N D 14 GENERA BASS ENB El eee sl ii NA 15 H OUTPUT PLANET SET ASSEMBLY 215 I SECONDARY PLANET SET ASSEMBLY 16 J INPUT PLANET SET ASSEMBLY je iri K GEAR END ASSEMBLY 18 L DRUM SECTION ASSEMBLY 19 M BRAKE SECTION ASSEMBLY ET uge AE 22 A a 23 RUFNER40WBIRINORIMAUERINL S NONE acc nc 24 VISCOSITY CARPE cc 27 TORQUE SPECIFIC ATIONS IGT AR pile 10 cccssccccsssscesenssseeensssceesnssaeeeenseceeesnseceeesnsscecensnssaeensnsaeenses 28 RUFNEK 100 ISOMETRIC DRAWING cooooiooccccocooccooococoncconcncnconnnncnnnnnnncn rn rca 29 SEL 0040 004 DOC REV 0 INTRODUCTI
11. LANET SET DISASSEMBLY 1 Remove the retaining rings 22 4 from the 3 Remove the planet gears 22 2 thrust planet pins 22 5 washers 22 6 and bearings 22 3 from the carrier 2 Remove the pins 22 5 from the carrier 22 1 by carefully tapping them out 4 Inspect the parts for wear or damage and replace if necessary z 7 Z x CV F SECONDARY PLANET SET DISASSEMBLY 1 Remove the retaining rings 23 4 from the 3 Remove the planet gears 23 2 thrust planet pins 23 5 washers 23 6 and bearings 23 3 from the carrier 2 Remove the pins 23 5 from the carrier 23 1 by carefully tapping them out 4 Inspect the parts for wear or damage and replace if necessary 252 zon G OUTPUT PLANET SET DISASSEMBLY 1 24 6 Remove the retaining rings 24 4 from the 4 planet pins 24 5 Remove the pins 24 5 from the carrier 5 24 1 by carefully tapping them out Remove the planet gears 24 2 thrust washers 24 6 and bearings 24 3 from the carrier z Remove the thrust plate 24 7 and the retaining ring 24 8 from the carrier Inspect the parts for wear or damage and replace if necessary GENERAL ASSEMBLY H OUTPUT PLANET SET ASSEMBLY 1 Insert the retaining ring 24 8 and the thrust 2 Being careful to line up the thrust washers plate 24 7 into the carrier 24 1 along with 24 6 and bearings 24 3 with the planet the gears 24 2 bearings 24 3
12. LAR 47 3 42939 KEY 48 1 43696 THRUST COLLAR 49 E i OMIT 50 1 42932 BALL BEARING 51 4 43880 CAPSCREW 52 7 42148 STATOR PLATE 53 6 32765 FRICTION DISC 54 1 42942 BRAKE PISTON 55 1 42335 O RING 56 1 42336 BACK UP RING 57 1 32186 O RING 58 1 42337 BACK UP RING 59 12 42230 BRAKE SPRING 60 4 28060 CAPSCREW 61 1 33094 O RING 62 1 34003 O RING 63 1 43165 2 SPEED HYDRAULIC MOTOR 64 1 44337 INPUT DRIVER 65 1 29043 RETAINING RING 66 2 44323 RETAINING RING 67 2 29162 BEARING 68 1 44338 BEARING HOUSING 25 RUFNEK 100 BILL OF MATERIAL continue 69 1 44335 BRAKE DRIVER 70 8 20650 CAPSCREW 71 8 20653 NUT 72 8 20652 LOCKWASHER 73 1 44048 RIGHT HAND FRAME 74 1 44049 LEFT HAND FRAME 75 1 43367 CARTRIDGE VALVE 76 1 42929 BRAKE BAND AIR CYLINDER 77 1 4343 BRAKE BAND ASSEMBLY 78 1 43368 MANIFOLD BLOCK 79 1 42029 COUNTERBALANCE BLOCK 80 3 42089 90 ADAPTER 81 1 42494 HOSE ASSEMBLY 82 1 42033 SWIVEL TEE 83 1 40280 FITTING 84 1 32145 CAPLUG 85 2 20521 NUT 86 2 20518 LOCKWASHER 87 1 42495 HOSE ASSEMBLY 88 1 43459 HOSE ASSEMBLY 89 3 21653 SET SCREW 90 1 42955 MOUNTING BRACKET 91 2 29472 CAPSCREW 92 2 21128 GREASE ZERK FITTING 93 1 13050 BREATHER 94 3 21684 PIPE PLUG 95 1 41759 CLUTCH 96 1 43828 CLEVIS 97 1 43891 AIR CYLINDER COVER 98 1 43941 AIR SHIFT KIT 99 2 43827 CLEVIS PIN 100 3 OMIT 101
13. ON 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 ASSEMBLY NUMBER EXPLANATION This manual is for design series 004 In the case of a major design change implementation a new design specification number will be issued for the winch A new manual will also be created for that specific design series DESIGN ASSEMBLY SERIES 81867 004 WINCH MODEL CODE RN100 PHLXOA 1 Gear Type Motor Type W Worm 1 Single Speed Gear Motor P Planetary 2 Two Speed Gear Motor Drive Type 3 Single Speed Geroler Motor H Hydraulic 4 Two Speed Geroler Motor M Mechanical 5 Piston Gearbox Position 6 Vane L Left X No Motor R Right Clutch Device viewed from rear of truck M Mechanical Input Shaft Location A Air F Front R Rear Cable Spooling O Over Drum X Does not apply v
14. and thrust pins 24 5 press the pins into the carrier washers 24 6 3 Replace the retaining rings 24 4 4 CAUTION gt If the pins are not lined up properly the thrust washer can be shattered during the 24 5 pressing operation gt 24 6 24 3 24 2 24 3 24 3 24 6 N NU A 24 1 24 8 24 7 l SECONDARY PLANET SET ASSEMBLY 1 Insert the thrust plate 23 6 into the carrier 2 Being careful to line up the thrust washers 23 1 along with the gears 23 2 bearings 23 6 and bearings 23 3 with the planet 23 3 and thrust washers 23 6 pins 23 5 press the pins into the carrier 3 Replace the retaining rings 23 4 A CAUTION 63 4 If the pins are not lined up pe properly the thrust washer 93 5 can be shattered during See the pressing operation 23 6 23 3 23 2 23 8 23 6 23 1 23 7 J INPUT PLANET SET ASSEMBLY 1 Insert the thrust plate 22 7 into the carrier 2 22 1 along with the gears 22 2 bearings 22 3 and thrust washers 22 6 4 CAUTION If the pins are not lined up properly the thrust washer can be shattered during the pressing operation 22 6 22 3 22 2 22 6 Being careful to line up the thrust washers 22 6 and bearings 22 3 with the planet pins 22 5 press the pins into the carrier Replace the retaining rings 22 4 22 4 22 5 22 1 22 7 K GEAR END ASSEMBLY 1 Bolt the ge
15. 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 across the mounting surface of the winch itself 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 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 eguipment PPE if reguired Check the
16. ar housing 10 loosely into both frames 73 74 Slide the output shaft 20 halfway into the gear housing 10 When reassembling apply grease to parts such as thrust washers o rings and seals Slide the thrust washer 38 onto the output shaft 20 Next install the output gear set 24 Rotate the thrust plate 24 7 in position and install the retaining ring 24 8 onto the shaft Push the gear set and shaft back into the housing until it stops against the thrust washer 38 NOTICE Make sure to line up all three planet gears in the output gear set with the gear housing as it starts into the housing Install the secondary gear housing 9 onto the gear housing 10 making sure not to damage the o ring 36 Use eight capscrews 35 and torque them to specification see torque specifications chart on page 28 of this manual Install the output sun gear 8 then install the thrust washer 37 onto the secondary gear set 23 Next install the secondary gear set 23 into the gear housing 10 NOTICE Make sure to line up all three planet gears in the secondary gear set with the gear housing and sun gear as it starts into the housing 93 478 A PON IA 74 18 Install the secondary sun gear 7 Making sure it s against the washer in the secondary gear set 23 Install the thrust washer 34 onto the input gear set 22 Insert the input gear set 22 into the gear housing 10
17. e air cylinder shaft until there is not space between the drum 11 and the brake band 77 Then tighten the jam nut to secure the adjusting nut 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 If necessary install the new drum clutch 14 using six capscrews 45 Torque to specified torque see page 28 of this manual Next align the coupler 12 with the keys 47 and slide it onto the output shaft 20 Install the sliding clutch 13 and yoke 17 onto the coupler 12 Continued on Page 20 DRUM SECTION ASSEMBLY CONTINUED 5 51 97 103 Install the outer thrust collar 48 aligning the half moon slots with the keys 47 Tightly hold the thrust collar against the keys and lock down the three set screws 89 Slide the brake housing 10 onto the output shaft Bolt the brake housing 10 loosely into both frames 73 74 Lower the drum so the weight of drum is supported by both the brake and gear housings The air line from the brake band air cylinder can be attached at this time Disengage the sliding clutch 13 so you can turn the drum freely and tighten all bolts through the frames to the proper torque specification see page 28 of this manual 20 Turn the drum to make sure it is not binding If necessary install the air cylinder 15 and th
18. e air cylinder cover 97 to the brake housing with four capscrews 51 and spacers 103 Install the bracket 110 to the brake housing using four capscrews 106 Attach the yoke 17 by installing clevis pins 99 into the bracket 110 and clevis 96 Install the cotter keys 108 into the clevis pins 99 to secure their positions Connect shop air to the cylinder and apply air both directions With the clutch fully engaged air applied there should be slight movement on the clutch plate in both directions Adjust clevis 96 and air cylinder jam nut accordingly M A Ste a CAUTION If a complete tear down is not necessary make sure the input shaft 21 does not move during removal of the drum If the shaft is allowed to move the input spacer 104 will fall into the gear set ultimately causing failure to the gear section of the winch The gear cover 3 will have to be removed to re position the spacer on the input shaft Re assemble the driver clutch assembly making sure the clutch is installed properly and checking to make sure the cam clutch is free turning in the pay in direction Measure the distance from the face of the brake housing to the end of the shaft as shown above If needed add shims 113 114 inside input driver 64 on motor side to achieve dimension shown above Install the bearing housing assembly that contains parts 50 and 68 into the brake housing 21
19. fall into the gear set ultimately causing failure to the gear section of the winch The gear cover 3 will have to be removed to re position the spacer on the input shaft C DRUM SECTION DISASSEMBLY 1 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 cotter keys 108 and clevis pins 99 connecting the yoke 17 to the bracket 110 amp air cylinder 15 NOTICE You may need to remove the air lines so it s a good idea to mark them for re assembly Support the weight of the drum with a hoist Remove the four cap screws 70 and the nuts and washers 71 72 on the bottom of the brake housing 16 Disconnect the airline running from the air cylinder 15 to the brake housing 16 Remove the brake housing by sliding it off of the output shaft 20 At this time you will need to remove two cap screws 70 nuts and washers 71 72 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 brake band air 4 CAUTION If a complete tear down is not necessary input shaft 21 does not move during removal of the drum to move 104 will fall into the gear set ultimately causing failure to the gear section of the winch The gear cover 3 will have to be removed to re position the spacer
20. iewed from rear of truck U Under Drum viewed from rear of truck 4 WARNING FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH 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 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 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 Indicates information or a company policy that NO TICE 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
21. l maintained to insure proper operation Good maintenance consists of four steps 1 A daily inspection to insure that there are no 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 The drum bushings are lubed thru two grease zerks located on drum barrel 4 Complete teardowns and component inspections Again severity and frequency of use will determine how often this should be done If 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 Rufnek series planetary winches are designed with a common oil reservoir for the gearbox and brake The winches are shipped from the factory filled with Mobilube SHC SAE 75W 90 synthetic gear oil which is satisfactory for operation in ambient temperatures from 40 F to 110 F If winch will be operated in temperatures outside this range contact Tulsa Winch for recommendation
22. rake Winch clutch is slipping Inspect the clutch and driver for wear and replace worn parts Relief valve setting may be too low to allow proper lifting Increase relief valve pressure setting Note Do not exceed recommended system pressures Load being lifted may be more than the winch s rating Reduce the load or re rig to increase mechanical advantage The motor shaft seal may have failed Replace this seal and reduce backpressure if that caused the shaft to fail Brake piston seals may have failed Service the brake section and replace worn parts Low flow rate Check the flow rate and increase if necessary Hydraulic motor worn out Replace the motor Winch not mounted squarely Check mounting and confirm that the winch is mounted on a level surface Clutch not disengaged Disengage the clutch RUFNEK 100 BILL OF MATERIAL 81867004 BOM AUGUST 2005 ITEM GTY P N DESCRIPTION 1 1 42031 HOSE ASSEMBLY 2 2 42438 STRAIGHT THREAD BRANCH TREE 3 1 44750 END COVER 4 1 42030 HOSE ASSEMBLY 5 2 41838 STRAIGHT ADAPTER 6 3 32477 CAPSCREW 7 1 42913 SECONDARY SUN GEAR 8 1 42914 OUTPUT SUN GEAR 9 1 42915 PRIMARY GEAR HOUSING 10 1 42916 GEAR HOUSING 11 1 42917 DRUM 12 1 42918 COUPLER 13 1 44576 SLIDING CLUTCH 14 1 43769 DRUM CLUTCH 15 1 44340 AIR CYLINDER 16 1 42922 BRAKE HOUSING 17 1 43882 CLUT
23. s The oil is drained by removing the drain plugs 18 amp 85 located at bottom of gear housing 10 amp bottom of brake cover 3 then remove the fill plugs 39 amp 81 located at the top of the gear housing 10 amp the top of the brake cover 3 Inspect the oil for signs of metallic particles and or burning and dispose of in a proper manner Then re install the drain plugs Fill the brake end with Mobilube SHC SAE 75W 90 1 2 quart then fill the gear end with of Mobilube SHC SAE 75W 90 oil 17 1 2 quarts and replace both of the fill plugs OIL CAPACITY 18 QUARTS GENERAL DISASSEMBLY A MOTOR DISASSEMBLY 1 Drain the oil from the brake assembly by 5 Remove the counterbalance valve 28 from removing the plug 94 from the brake cover the counterbalance block 79 and inspect 18 the metering hole to make sure it is not obstructed Also inspect the o rings on 2 Remove hoses 1 4 81 87 8 88 valve to insure that they are not flat or cut Replace if necessary 3 Remove the counterbalance block 79 and the manifold block 78 from the motor by 6 removing the four capscrews 25 Motors and counterbalance valves are not serviceable in the field Return them to an authorized dealer for service 4 Remove the motor 63 from the winch by removing four capscrews 30 7 Inspect o rings 26 8 62 for damage 81 M s m a a ki x 94 E oc BO N ED Na x Nr lof l um ib x N SP
24. ston Grasp the brake driver clutch assembly assembled items 64 65 66 67 69 and remove it from the brake housing Continued on page 8 BRAKE BRAKE SECTION DISASSEMBLY CONTINUED 5 Remove the stator plates 52 and friction Then remove the second bearing 67 from discs 53 from the brake housing and the input driver check them for excessive wear and replace if necessary Be sure to check the AA WARNING top stator plate for scoring caused by the A WARNING removal of the piston and polish if Notice the direction of lock up necessary Friction discs should measure on the clutch for re assembly no less than 055 in thick and stator plates should measure no less than 068 in thick 7 Remove the bearing housing 68 and inspect the bearing 50 6 To disassemble the brake driver clutch assembly remove the retaining ring 66 8 lf the bushing or seal in the brake housing from either end of the driver Then remove needs to be replaced follow the drum the brake driver 69 and bearing 67 from section disassembly and reassembly the input driver Next remove the sprag sections of this manual prior to reassembly clutch 95 Finally remove the retaining of the brake ring 66 from the other end of the driver 4 CAUTION If a complete tear down is not necessary make sure the input shaft 21 does not move during removal of the EN drum If the shaft is allowed to move the input spacer 104 will
25. tion see page 28 of this manual 5 NOTICE A Make sure you install the motor with the belly of it down and the case drain port up 2 If removed install the cartridge valve 75 3 Install the counter balance valve 28 into the counterbalance block 79 81 87 i S y N be a 60 L A i be s i d S i 83 5 gt 63 gt g s 5 5 75 9 s Y 30 a 0 2 SA LS di f 26 gt 8 m 78 u 80 26 ag 88 22 Install the o ring 26 into the manifold block 78 and counterbalance block 79 Install the manifold block 78 and counter balance block 79 using four capscrews 25 Install hoses 1 4 81 87 and 88 Remove the oil level plugs 86 amp 94 from the brake cover 18 and gearbox cover 3 Fill the brake and gearbox through the oil fill hole located on top of the gearbox with the proper oil until the oil reaches the oil level holes Replace the oil level plugs S OL LEVEL W UT Q ANT HOLES RO A gt u NJ A 94 28 28 25 a SS amp METERING T HOLE wz ka 4 pal TROUBLESHOOTING FAILURE Winch won t hold load Winch will not raise the load it should Oil leaks from vent located on the top of the gearbox Winch runs too slow Cable drum won t free spool 23 PROBABLE CAUSE Excessive backpressure in the system Check the system for restrictions and reduce the backpressure Brake discs are worn out discs Replace b
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