RN80P Service Manual
Contents
1. SEQ QTY P N DESCRIPTION 88 4 20524 CAPSCREW 89 1 32411 HEX PLUG 90 1 43877 CLUTCH BRACKET 91 1 43835 AIR CYLINDER COVER 92 3 42089 90 ADAPTER 93 1 43368 MANIFOLD BLOCK 94 3 44436 SHAFT KEY 95 OMIT 96 gt OMIT 97 4 43078 SPACER 98 1 34003 O RING 99 1 939243 CLEVIS PIN 100 3 20514 COTTER PIN 101 1 43367 12 VOLT CARTRIDGE VALVE 102 OMIT 103 5 5 OMIT 104 OMIT 105 1 44340 AIR CYLINDER 106 4 43372 CAPSCREW 107 2 32182 O RING 108 1 41867 COUNTERBALANCE VALVE 109 1 44736 INTELLIGUARD LOGO PLATE 110 OMIT 111 OMIT 112 OMIT 113 1 29043 RETAINING RING 114 1 31543 O RING 115 OMIT 25 Z Wi Tulsa Winch 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 8 EB AB GE 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 30 716 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 90 212 159 122. 3 WASHER 6 4 BEARING 6 5 SPACER 3 6 PLANET GEAR 3 7 RETAINING RING 3 12 G OUTPUT PLANET SET DISASSEMBLY 1 Remove the retaining rings 7 from the 3 Remove the planet gears 2 thrust washers carrier 3 bearings 6 and spacers 5 from the carrier 2 Remove the planet pins 4 from the carrier 1 by carefully tapping them out 4 Inspect the parts for wear or damage and replace if necessary OUTPUT GEAR SET 40 WASHER PLANET PIN SPACER 4 5 6 BEARING 7 RETAINING RING 3 13 GENERAL ASSEMBLY H OUTPUT PLANET SET ASSEMBLY 1 Insert the gears 2 bearings 6 spacers 2 Being careful to line up the thrust washers 5 and thrust washers 3 into the carrier 3 and bearings 6 with the planet pins 4 1 press the pins into the carrier 3 Replace the retaining rings 7 CAUTION If the pins are not lined up properly the thrust washer can be shattered during the pressing operation OUTPUT GEAR SET 40 WASHER PLANET PIN BEARING 4 5 SPACER 6 7 RETAINING RING 3 1 1 SECONDARY PLANET SET ASSEMBLY Insert the gears 6 bearings 4 spacers 2 Being careful to line up the thrust washers 5 and thrust washers 3 into the carrier 3 and bearings 4 with the planet pins 2 1 press the pins into the carrier 3 Replace the retaining rings 7 CAUTION If the pins are not
3. NOTICE 7 Remove the oil level plugs 81 amp 86 from Make sure you install the the brake cover 2 and gearbox cover 55 motor with the belly of it Fill the brake and gearbox through the oil fill down and the case drain hole located on top of the gearbox with the port up proper oil until the oil reaches the oil level holes Replace the oil level plugs See 2 If removed install cartridge valve 101 page 5 of this manual 3 Install the o ring 107 into the manifold block 93 and counterbalance block 76 4 Install the counter balance valve 108 into the counterbalance block 76 OIL LEVEL HOLES 21 TROUBLESHOOTING FAILURE PROBABLE CAUSE Winch won t hold load Excessive back pressure in the system Check the system for restrictions and reduce the backpressure Brake discs are worn out Replace brake discs Winch clutch is slipping Inspect the clutch and driver for wear and replace worn parts Winch will not raise the load it should 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 Oil leaks from the vent located on the top of the The motor shaft seal may have failed Replace gearbox this seal and reduce backpressure if that caused the shaft seal to fail Brake pis
4. GEAR SET 42 1 4398 INPUT GEAR SET 43 2 44428 THRUST WASHER 23 RUFNEK 80 BILL OF MATERIAL CONTINUED SEQ QTY P N DESCRIPTION 44 3 32477 CAPSCREW 45 1 44430 SECONDARY SUN GEAR 46 1 44431 OUTPUT SUN GEAR 47 1 43699 RETAINING RING 48 1 43828 CLEVIS 49 2 43827 CLEVIS PIN 50 3 21653 SET SCREW 51 2 21128 ZERK GREASE FITTING 52 1 42932 BALL BEARING 53 1 43696 THRUST COLLAR 54 1 43459 HOSE ASSEMBLY 55 1 44736 COVER 56 1 42495 HOSE ASSEMBLY 57 2 28933 O RING 58 1 44727 PRIMARY HOUSING 59 1 29496 O RING 60 1 44419 GEAR HOUSING 61 8 30203 CAPSCREW 62 8 20318 NUT 63 8 20559 LOCKWASHER 64 1 44434 RIGHT HAND FRAME 65 1 44435 LEFT HAND FRAME 66 1 44461 BRAKE BAND 67 1 43882 CLUTCH YOKE 68 1 42929 BRAKE BAND AIR CYLINDER 69 4 43880 CAPSCREW 70 2 20525 CAPSCREW 71 2 20521 NUT 72 2 20518 LOCKWASHER 73 1 42955 AIR SHIFT MOUNTING BRK 74 1 31582 O RING PLUG 75 1 13050 BREATHER 76 1 42029 1200W COUNTERBALANCE BLOCK 77 1 42031 HOSE ASSEMBLY 78 2 42438 STRAIGHT THREAD BRANCH TEE 79 1 40280 FITTING 80 1 42030 HOSE ASSEMBLY 81 4 21684 PLUG PIPE 82 2 41838 STRAIGHT ADAPTER 83 OMIT 84 1 43834 AIR SHIFT TUBING amp FITTING KIT 85 1 42392 O RING PLUG 86 2 43402 O RING PLUG 87 1 42033 SWIVEL TEE 24 RUFNEK 80 BILL OF MATERIAL CONTINUED
5. 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 winch cable should be inspected daily for serviceability 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 well maintained to insure proper operation Good maintenance consists of four steps 1 Adaily 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 thru grease fitting
6. the brake assembly by removing the plug 81 from the bottom of the brake cover 2 Remove hoses 4 54 56 77 amp 80 Remove the counterbalance block 76 and the manifold block 93 from the motor by removing the four cap screws 106 Remove the motor from the winch by removing four capscrews 88 6 5 Remove the counterbalance valve 108 from the counterbalance block 76 and inspect the metering hole to make sure it is not obstructed Also inspect the o rings on valve 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 Inspect o rings 98 amp 107 for damage 6 S METERING HOLE B BRAKE SECTION DISASSEMBLY 1 Evenly remove the four cap screws 3 that hold the brake cover 2 in place Spring pressure will raise the cover up as the cap screws are loosened Carefully remove the cover 2 from the brake housing 20 Inspect the o ring 6 on cover for damage Remove the springs 7 from the piston 5 and check the free height Each spring should measure at least 1 240 inches with no force on them Remove the piston 5 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 shop air to slowl
7. 3 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 5 into the brake housing 20 and gently tap it down until it is seated making sure not to damage the o rings 8 10 or back up rings 9 11 6 Install the springs 7 into the spring pockets in the piston If working in a horizontal position coat the bottom of each spring with chassis lube to keep it in position Install the cover 2 onto the brake housing 20 using four capscrews 3 making sure the cover is correctly oriented Then draw it down evenly alternating between opposite capscrews being careful not to damage the o ring 6 Check the brake release with a portable hydraulic pump Full release should be obtained at 400psi plus or minus 20psi Also check the brake for proper operation by applying 105psi to the brake port and adapiing a torque wrench to the Intelliguard shaft The torque in the payout should be 134 to 154 ft lbs MOTOR ASSEMBLY O O O OO 1 Install the o ring 98 then the motor 1 and 5 Install the manifold block 93 and counter secure it with four capscrews 88 Tighten balance block 76 using four capscrews capscrews to the proper torque 106 specification see page 27 of this manual 6 Install hoses 4 54 56 77 and 80
8. 7 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 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 BOLT TORQUE LB KWD 12 TORQUE COEFFICIENT K 0 20 DRY W PRELOAD TENSION D NOMINAL BOLT SIZE IN ALL TORQUE VALUE TOLERANCES ARE 5 K 0 15 PLATED 27 K 0 12 LUBRICATED RUFNEK 80 ISOMETRIC DRAWING 4 CAUTION DO NOT USE MAGNETS ON OR AROUND WINCH 28
9. DESIGN SERIES 004 Tulsa Winch RUFNEK 80 RUFNEK SERVICE MANUAL win Imtelliguard INTRODUCTION AND THEORY OF OPERATION ccsscssssssessssassessnsesnecsansessanstnaenstsaenateeesanseeneesanseeses 2 ASSEMBLY NUMBER EXPLANATION 7 6 65 2 WINCH MODEL CODES 2 90 0 5 GENERAL DISASSEMBLY 0 0 6 A MOTOR DISASSEMBLY lt 5 MER 6 BRAKE SECTION 7 DRUM SECTION DISASSE NESEY 8 D GEAR SECTION DISASSEJ BIY Eg 10 INPUT PLANET SET 11 SECONDARY PLANELSETBIS SSEMBRESAN 12 G OUTPUT PLANELSETDISAGSEMBLY TN 12 GENERAL 5 12 H OUTPUT PLANET SEPASSEMBIY af _ 12 SECONDARZ EBANEFSET ASSEMBLE SZA MI 8 12 J INPUT PL NEFSETASSEMSKY 12 GEAR 0 12 L DRUM 12 BRAK
10. ESEGTIONASSEMEBTIP 996 9 22 9 12 40 49 6 44 9 699 5 6 12 180 079 7 12 RUFNEK 80 BILL OF MATERIAL 12 VISCOSITY CHART 2209009 12 TORQUE 7 12 80 ISOMETRIC 12 SEL 0041 004 D0C REV 0 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 val
11. ISASSEMBLY 1 To remove the drum first disconnect the cable from the cable clamp 35 and lay aside If removing the drum from the motor end with the motor and brake disassembled first remove the cotter keys 100 and clevis pins 49 connecting the yoke 67 to the bracket 90 amp air cylinder 105 Second remove the eight cap screws 29 amp 69 four spacers 97 air cylinder cover 91 air cylinder 105 and bracket 90 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 61 along with the nuts and washers 63 62 on the bottom of the brake housing 20 Disconnect the airline running from the air cylinder 68 to the brake housing 20 Remove the brake housing by sliding the housing off the output shaft 38 At this time you will need to remove the two cap screws 70 nuts and washers 71 72 from the frames 64 or 65 You can now remove the brake band assembly 66 Note which frame the mounting bolts are on for re assembly Inspect and replace if needed Remove the outer thrust collar 53 by loosening the three set screws 50 Remove the yoke 67 sliding clutch 27 and coupler 30 Remove the three keys 94 and the inner thrust collar 24 Remove the drum using a hoist Inspect the bushings 31 in both ends of the drum NOTICE You should also inspect the bushing and
12. e of a hoist With the weight of the drum supported install the brake band assembly 66 along with the bracket 73 capscrews 70 nuts 71 and washers 72 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 68 making sure the rod of the air cylinder 68 is going through the bracket on the brake band 66 Secure it to the bracket 73 with the clevis pin 99 and cotter key 100 Tighten the adjusting nut on the air cylinder shaft until there is not space between the drum NOTICE The brake band may need to be readjusted once it s in the field 34 and the brake band 66 Then tighten the jam nut to secure the adjusting nut Install the inner thrust collar 24 making sure the half moon slots are lined up with the key slots in the output shaft 38 Tap the three keys 94 into their slots in the output shaft Align the coupler 30 with the keys 94 and slide it onto the output shaft 38 Install the sliding clutch 27 and yoke 67 onto the coupler 30 Install the outer thrust collar 53 aligning the half moon slots with the keys 94 Tightly hold the thrust collar 53 against the keys and lock down the three set screws 50 Slide the brake housing 20 onto the output shaft 38 Continued on page 19 DRUM SECTION ASSEMBLY CONTINUED 7 Bolt the brake housing 20 loosely into both frame
13. ecommended references are but not limited to ANSI 830 OSHA 1910 AWS 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 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 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
14. he inner and outer thrust washers 43 Inspect and replace if necessary 10 Remove the sun gear 45 and secondary gear set 41 Inspect and replace if necessary Remove the primary housing 58 by removing eight capscrews 32 Inspect the o ring 59 and replace if necessary Remove the spacer 28 and sun gear 46 Inspect for wear and replace if necessary Remove the snap ring 47 from the output shaft 38 Remove the output gear set 40 and thrust washer 37 necessary Inspect and replace if E INPUT PLANET SET DISASSEMBLY 1 Remove the retaining rings 6 from the 3 Remove the planet gears 4 thrust washers carrier 1 3 and bearings 5 from the carrier 2 Remove the planet pins from the carrier 1 4 Inspect the parts for wear or damage and by carefully tapping them out replace if necessary INPUT GEAR SET 42 ITEM NO DESCRIPTION QTY 1 CARRIER 1 2 PLANET PIN 3 3 WASHER 6 4 PLANET GEAR 3 5 BEARING 3 6 RETAINING RING 3 F SECONDARY PLANET SET DISASSEMBLY 1 Remove the retaining rings 7 from the 3 Remove the planet gears 6 thrust washers carrier 1 3 bearings 4 and spacers 5 from the carrier 2 Remove the planet pins 2 from the carrier 1 by carefully tapping them out 4 Inspect the parts for wear or damage and replace if necessary SECONDARY GEAR SET 41 ITEM NO DESCRIPTION QTY 1 CARRIER 1 2 PLANET PIN 3
15. lined up properly the thrust washer can be shattered during the pressing operation SECONDARY GEAR SET 41 DESCRIPTION QTY CARRIER 1 PLANET PIN 3 WASHER 6 BEARING 6 SPACER 3 PLANET GEAR 3 7 RETAINING RING 3 oS INPUT PLANET SET ASSEMBLY 1 Insert the gears 4 bearings 5 and thrust 2 Being careful to line up the thrust washers washers 3 into the carrier 1 3 and bearings 5 with the planet pins 2 press the pins into the carrier 1 3 Replace the retaining rings 6 CAUTION If the pins are not lined up properly the thrust washer can be shattered during the pressing operation INPUT GEAR SET 42 ITEM NO DESCRIPTION QTY 1 CARRIER 1 2 PLANET PIN 3 3 WASHER 6 4 PLANET GEAR 3 5 BEARING 3 6 RETAINING RING 3 K GEAR END ASSEMBLY 1 Bolt the gear housing 60 loosely into both 6 Install the secondary sun gear 45 frames 64 65 7 Install the inner thrust washer 43 onto the 2 When reassembling apply grease to parts input gear set 42 Insert the input gear set such as thrust washers o rings and seals 42 into the ring gear 22 making sure it is Install the output shaft 38 into the gear against the thrust washer 43 Put the outer housing 60 Slide the thrust washer 37 thrust washer 43 in place and slide the onto the output shaft 38 Next install the input shaft 39 through the sun gears and outp
16. s 64 65 Lower the drum so the weight of the 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 27 so you can turn the drum freely and tighten all bolts through the frames to the proper torque specification see page 27 of this manual Turn the drum to make sure it is not binding If necessary install the air cylinder 105 and the air cylinder cover 91 to the brake housing with four spacers 97 capscrews 69 and Install the bracket 90 to the brake housing using four capscrews 29 Attach the yoke 67 by installing clevis pins 49 into the bracket 90 and clevis 48 Install cotter keys 100 to clevis pins 49 to secure their positions Connect shop air to the cylinder and apply air in both directions With the clutch fully engaged air applied there should be slight movement on the clutch plate in both directions Adjust clevis 48 and air cylinder jam nut accordingly M BRAKE SECTION ASSEMBLY 1 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 Install the bearing housing assembly that contains parts 16 and 52 into the brake housing Install the driver clutch assembly onto the Intelliguard shaft 39 Install the stator plates 12 and friction discs 1
17. s 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 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 recommendations The oil is drained by removing the drain plugs 85 amp 81 located at bottom of adapter cover 58 and bottom of brake cover 2 Then remove the fill plugs 74 amp 81 located at the top of the gear housing 60 and the top of the brake cover 2 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 Mobilube SHC SAE 75W 90 oil 9 quarts and replace both of the fill plugs OIL CAPACITIES 9 5 QUARTS GENERAL DISASSEMBLY A MOTOR DISASSEMBLY Drain the oil from
18. seal 21 25 that are located in the end of the brake housing 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 NOTICE BAD 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 WARNING FACE 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 D GEAR SECTION DISASSEMBLY 1 Drain the oil by removing the plug 85 located on the bottom of the adapter cover 58 To disassemble the gear section remove the Intelliguard spacer 39 from the outer cover 55 by removing three capscrews 44 Inspect the gear teeth on the Intelliguard 39 for wear The Intelliguard system is not serviceable in the field Return to an authorized dealer for service Remove the outer cover 55 by removing the ten capscrews 112 Inspect the o rings 57 amp 114 for wear and replace if necessary Remove the input gear set 42 along with t
19. ton seals may have failed Service the brake section and replace worn parts Winch runs too slow Low flow rate Check the flow rate and increase if necessary Hydraulic motor worn out Replace the motor Cable drum won t free spool Winch not mounted squarely Check mounting and confirm that the winch is mounted on a level surface Clutch not disengaged Disengage the clutch 22 RUFNEK 80 BILL OF MATERIAL SEQ QTY P N DESCRIPTION 1 1 43152 HYDRAULIC MOTOR 2 1 43419 BRAKE COVER 3 6 28060 CAPSCREW 4 1 42494 HOSE ASSEMBLY 5 1 42942 BRAKE PISTON 6 1 33094 O RING 7 12 42230 BRAKE SPRING 8 1 32186 O RING 9 1 42337 BACK UP RING 10 1 42335 O RING 11 1 42336 BACK UP RING 12 7 42148 STATOR PLATE 13 6 32765 FRICTION DISC 14 1 44335 BRAKE DRIVER 15 2 29162 BEARING 16 1 44338 BEARING HOUSING 17 2 44323 RETAINING RING 18 1 41759 CLUTCH 19 1 44337 INPUT DRIVER 20 1 44420 BRAKE HOUSING 21 2 44439 BUSHING 22 OMIT 23 2 OMIT 24 1 42938 THRUST COLLAR 25 2 44690 OIL SEAL 26 3 994188 THRUST RACE 27 1 44576 SLIDING CLUTCH 28 1 44498 SUN GEAR SPACER 29 4 29614 CAPSCREW 30 1 44422 COUPLER 31 2 42868 BUSHING 32 8 30204 CAPSCREW 33 2 33324 WASHER 34 1 44423 WELDMENT DRUM 35 1 44424 CABLE CLIP 36 OMIT 37 1 44425 THRUST WASHER 38 1 44426 OUTPUT SHAFT 39 1 4479 INTELLIGUARD SYSTEM 40 1 4397 OUTPUT GEAR SET 41 1 4399 SECONDARY
20. ut gear set 40 Then install the output shaft 38 Let the input shaft retaining ring 47 onto the output shaft 38 protrude out on the gear end so that all of Push the gear set and shaft back into the the spline is showing housing until it stops against the thrust washer 37 8 Put the cover 55 on and secure it with eight capscrews 3 being careful not to damage the o ring 59 Install the NOTICE Intelliguard sensor 39 into the cover 55 Make sure to line up all with three capscrews 44 again making three planet gears in the sure not to damage the o ring 114 add output gear set with the locktite and secure it with three capscrews gear housing as it starts 44 into the housing Install the sun gear 46 and spacer 28 NOTICE Make sure the input shaft 4 Install the primary housing 58 onto the engages the gear in gear housing 60 with eight capscrews 32 the Intelliguard correctly making sure not to damage the o ring 59 and torque them to specification see page 27 of this manual 5 Install the secondary gear set 41 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 L DRUM SECTION ASSEMBLY 1 After inspecting and replacing the necessary parts such as the drum bushings 31 Install the drum 34 onto the output shaft 38 This part is very heavy and you will need the assistanc
21. ve 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 series designation number will be issued for the winch A new manual will also be created for that specific design series DESIGN ASSEMBLY SERIES 82021 004 WINCH MODEL CODES 80 PHLXOAI1 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 Cable Spooling X Does not apply O Over Drum viewed from rear of truck U Under Drum viewed from rear of truck WARNING FAILURE 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 R
22. 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 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
23. y pressurize the brake cavity to remove the piston from the brake housing 20 Inspect the o rings 8 10 and back up rings 9 11 on the piston replace if necessary Grasp the brake driver clutch assembly assembled items 14 15 17 18 19 113 and remove it from the brake housing Remove the stator plates 12 and friction discs 13 from the brake housing and check them for excessive wear Replace the parts if necessary Be sure to check the top stator plate for scoring caused by the removal of the piston and polish if needed 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 17 from either end of the driver Then remove the brake driver 14 and bearing 15 from the input driver 19 Next remove the sprag clutch 18 Finally remove the retaining ring 17 from the other end of the driver then remove the second bearing 52 from the input driver WARNING Notice the direction of lock up on the clutch for re assembly Inspect the input driver and brake driver for wear replace if necessary Remove the bearing housing 16 and inspect the bearing 52 If the bushing or seal in the brake housing needs to be replaced follow the drum section disassembly reassembly sections of this manual prior to reassembly of the brake C DRUM SECTION D
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