Dover TWG RUFNEK 50P Service & Repair Manual
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Dover TWG RUFNEK 50P Service & Repair Manual

Dover TWG RUFNEK 50P Service & Repair Manual

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RUFNEK 50P
Service/Repair Manual
INTRODUCTION AND THEORY OF OPERATION ......................................................................................... 4
MAINTENANCE AND SERVICE .................................................................................................................... 5
RECOMMENDED OILS ................................................................................................................................ 6
OIL CHANGE ............................................................................................................................................... 7
DISASSEMBLY ............................................................................................................................................ 8
MOTOR DISASSEMBLY ..................................................................................................................................8
BRAKE SECTION DISASSEMBLY ...................................................................................................................9
DRUM SECTION DISASSEMBLY .................................................................................................................. 10
CLUTCH INSPECTION ................................................................................................................................. 11
GEAR SECTION DISASSEMBLY ................................................................................................................... 12
INPUT PLANET SET DISASSEMBLY ............................................................................................................. 13
SECONDARY PLANET SET DISASSEMBLY ...................................................... E
OUTPUT PLANET SET DISASSEMBLY .......................................................................................................... 14
ASSEMBLY ................................................................................................................................................ 15
OUTPUT PLANET SET ASSEMBLY ................................................................................................................ 15
SECONDARY PLANET SET ASSEMBLY ............................................................. E
INPUT PLANET SET DISASSEMBLY ............................................................................................................. 16
GEAR END ASSEMBLY ................................................................................................................................. 17
DRUM SECTION ASSEMBLY ........................................................................................................................ 18
BRAKE SECTION ASSEMBLY ....................................................................................................................... 20
MOTOR ASSEMBLY ...................................................................................................................................... 22
TROUBLESHOOTING ................................................................................................................................ 23
TORQUE SPECIFICATIONS CHART ........................................................................................................... 24
BILL OF MATERIAL ................................................................................................................................... 25
CROSS SECTIONAL ASSEMBLY DRAWING ............................................................................................... 28
EXPLODED ASSEMBLY DRAWING ............................................................................................................ 29
INSTALLATION DRAWING ....................................................................................................................... 30
SEL-0143-000
REV 0 JUNE 2014
DESIGN SERIES 001

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  • Page 1: Table Of Contents

    RUFNEK 50P Service/Repair Manual DESIGN SERIES 001 TABLE OF CONTENTS INTRODUCTION AND THEORY OF OPERATION ..................4 MAINTENANCE AND SERVICE ........................5 RECOMMENDED OILS ..........................6 OIL CHANGE ............................... 7 DISASSEMBLY ............................8 MOTOR DISASSEMBLY ..........................8 BRAKE SECTION DISASSEMBLY ........................9 DRUM SECTION DISASSEMBLY ........................
  • Page 2 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.
  • Page 3 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. ...

  • Page 4: Introduction And Theory Of Operation

    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.

  • Page 5: Maintenance And Service

    MAINTENANCE AND SERVICE For safe and consistent operation of TULSA WINCH hoists, swing drives, and winches, a regular program of preventive maintenance is strongly recommended. Regular oil changes with the correct oil for the ambient temperature conditions and an annual inspection of the wear components will help ensure a long life for your planetary geared products.

  • Page 6: Recommended Oils

    RECOMMENDED OILS FOR STANDARD TEMP APPLICATIONS -10˚F THRU 150˚F ( -23˚C THRU 66˚C) oil temp. *Gearbox oil (GL-5): Any GL-5 75W-90 Oil FOR LOW TEMP APPLICATIONS -40˚F THRU 180˚F (-40˚C THRU 82˚C) oil temp. *Gearbox oil (GL-5): Shipped from the factory filled with Mobilube SHC SAE 75W-90 synthetic gear oil *All gearbox oils must meet MIL-PRF2105 &...

  • Page 7: Oil Change

    OIL CHANGE The oil is drained by removing the drain plugs (81 & 86) located at bottom of gear housing (60) (Figure 1) and bottom of brake cover (2) (Figure 2). Then remove the fill plugs (81, 74 & 75) located at the top of the gear housing (3) and the top of the brake cover (2).

  • Page 8: Disassembly

    DISASSEMBLY MOTOR DISASSEMBLY 1. Drain the oil from the brake assembly by removing the plug (81) from the bottom of the brake cover (2). 2. Remove hoses (42, 45, 58, 79, & 80). 3. Remove the counterbalance block (32) and the manifold block (56), from the motor (1) by removing the four cap screws (88).

  • Page 9: Brake Section Disassembly

    BRAKE SECTION DISASSEMBLY 1. Evenly remove the four capscrews (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) for damage. 2.

  • Page 10: Drum Section Disassembly

    DRUM SECTION DISASSEMBLY 1. To remove the drum, first disconnect the cable from the U-bolt (35) and lay aside. If removing the drum from the motor end with the motor and brake disassembled, first remove the cotter keys (93) and clevis pins (100) connecting the yoke (87) to the bracket (101) and air cylinder (67). You may need to remove the airlines, mark them for re-assembly.

  • Page 11: Clutch Inspection

    CLUTCH INSPECTION GOOD This picture illustrates a sliding and drum clutch with the proper reverse draft and minimum edge wear. The reverse draft ensures the clutch stays engaged during pay-in. Without the correct draft, the clutch could dis-engage unpredictably. CLUTCH REPLACEMENT CRITERIA 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...

  • Page 12: Gear Section Disassembly

    GEAR SECTION DISASSEMBLY 1. Drain the oil by removing the plug (86) located on the bottom of the gear housing (60). 2. To disassemble the gear section, remove the Intelliguard™ (39) from the end cover (55) by removing three capscrews (44). Inspect the gear teeth on the Intelliguard™ (39) for wear. The Intelliguard™...

  • Page 13: Input Planet Set Disassembly

    INPUT PLANET SET DISASSEMBLY 1. Remove the retaining rings (41-5) from the planet pins (41-6). 2. Remove the pins from the carrier (41-1) by carefully tapping them out. 3. Remove the planet gears (41-3), thrust washers (41-4), and bearings (41-2) from the carrier (42-1).

  • Page 14: Output Planet Set Disassembly

    OUTPUT PLANET SET DISASSEMBLY 1. Remove the retaining rings (40-4) from the planet pins (40-3). 2. Remove the pins from the carrier (40-1) by carefully tapping them out. 3. Remove the planet gears (40-2), thrust washers (40-8), and bearings (40-6) from the carrier (40-1).

  • Page 15: Assembly

    ASSEMBLY OUTPUT PLANET SET ASSEMBLY 1. Insert the output shaft (40-9) into the carrier (40-1) and install the retaining ring (40-7). 2. Next insert the thrust plate (40-5) into the carrier along with the gears (40-2), bearings (40-6), and washers (40-8). 3.

  • Page 16: Input Planet Set Disassembly

    INPUT PLANET SET DISASSEMBLY 1. Insert the thrust plate (41-7) into the carrier (41-1) along with the gears (41-3), bearings (41- 2), and thrust washers (41-4). 2. Being careful to line up the thrust washers (41-4) and bearings (41-2) with the planet pins (41- 6), press the pins into the carrier (42-1).

  • Page 17: Gear End Assembly

    GEAR END ASSEMBLY 1. Bolt the gear-housing (60) loosely into both frames (64, 65) using four capscrews, washers, and nuts (61, 62, & 63). When reassembling, apply grease to parts such as the thrust washers, o-rings, and seals. Slide the thrust washer (37) onto the output shaft (40-9). Next, install the output gear set (40). Push the gear set and shaft back into the housing until it stops against the thrust washer (37).

  • Page 18: Drum Section Assembly

    DRUM SECTION ASSEMBLY 1. After inspecting and replacing the necessary parts, such as the drum bushings (31), install the bushing (4) onto the output shaft (40-9). 2. Install the drum (34) onto the output shaft (40-9). This part is very heavy and you will need the assistance of a hoist.
  • Page 19 DRUM SECTION ASSEMBLY CONT. 14. Attach the yoke (87) by installing clevis pins (93) into the bracket (101) and the air cylinder clevis (92). Install the cotter pins (100) into the clevis pins (93) in order to secure their positions. 15.

  • Page 20: Brake Section Assembly

    BRAKE SECTION ASSEMBLY 1. Re-assemble the driver/clutch assembly (14, 17, 18, 19, 52) making sure the clutch is installed properly and checking to make sure the cam clutch is free turning in the pay in direction. 2. Measure the distance from the face of the brake housing to the end of the shaft as shown (Figure 3).
  • Page 21 BRAKE SECTION ASSEMBLY CONT. 10. 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 0psi to the brake port and adapting a torque wrench to the input shaft. The torque in the payout should be 360 to 440 ft-lbs.

  • Page 22: Motor Assembly

    MOTOR ASSEMBLY 1. Install the o-ring (98) onto the motor (1) and install the motor using four capscrews (88). Tighten the capscrews to the proper torque specification (see page 25 of this manual). Make sure to install the motor with the belly down and the case drain port up.

  • Page 23: Troubleshooting

    TROUBLESHOOTING Winch won’t hold load Possible Solutions: 1. There is excessive back pressure in the hydraulic system. Check the system for line restrictions and reduce the back pressure. 2. The brake discs are worn. Replace the brake discs. Friction discs should measure no less than 0.055 inches thick and the stator plates should measure at least 0.064 inches thick.

  • Page 24: Torque Specifications Chart

    TORQUE SPECIFICATIONS CHART Plated Lubricated Plated Lubricated Grade 5 Grade 5 Grade 5 Grade 8 Grade 8 Grade 8 Torque Torque Torque Torque Torque Torque Nominal Size *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) 5/16 5/16 7/16 7/16 9/16 9/16 1019 1-1/8 1288 1-1/8...

  • Page 25: Bill Of Material

    BILL OF MATERIAL ITEM DESCRIPTION QTY. MOTOR,HYD. COVER, BRAKE CAPSCREW BUSHING PISTON, BRAKE O-RING SPRING, BRAKE O-RING RING, BACK-UP O-RING RING, BACK-UP PLATE, STATOR DISC, FRICTION DRIVER BRAKE BEARING, NEEDLE HOUSING, BEARING RING, RETAINING CLUTCH, SPRAG BRAKE, DRIVER, BLANK HOUSING, BRAKE CAPSCREW RING, RETAINING THRUST COLLAR...
  • Page 26 O-RING VALVE, COUNTERBALANCE PLUG, HEX, ORING BEARING CAPLUG VALVE, CARTRIDGE COVER BLOCK, MANIFOLD ADAPTER, 90 DEGREE HOSE O-RING HOUSING, GEAR CAPSCREW LOCKWASHER FRAME, R.H. FRAME, L.H. BRAKE BAND, ASS'Y CYLINDER, AIR CYLINDER, AIR,BRAKE BAND CAPSCREW CAPSCREW LOCKWASHER MOUNTING, BRACKET, AIR CYLINDER PLUG, ADAPTER BREATHER TEE, SWIVEL...
  • Page 27 LABEL, CLUTCH OUT FITTING, GREASE ZERK, 45 DEG COLLAR, THRUST CAPSCREW PLATE, LOGO, INTELLIGUARD U-BOLT TAG, RUFNEK RACE, THRUST WASHER, HARDENED STEEL CUP EXP PLG HOLLOW LOCK SOCKET TUBING CUP EXP PLG...

  • Page 28: Cross Sectional Assembly Drawing

    CROSS SECTIONAL ASSEMBLY DRAWING...

  • Page 29: Exploded Assembly Drawing

    EXPLODED ASSEMBLY DRAWING...

  • Page 30: Installation Drawing

    INSTALLATION DRAWING...

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