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Tulsa RUFNEK 45 Service Manual

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SERVICE MANUAL
GENERAL INFORMATION .......................................................................................................................... 4
INTRODUCTION AND THEORY OF OPERATION .................................................................................................................... 4
ASSEMBLY NUMBER EXPLANATION ...................................................................................................................................... 4
WINCH BREAK-IN ...................................................................................................................................................................... 4
MODEL CODES ........................................................................................................................................... 5
MAINTENANCE ............................................................................................................................................ 6
OIL LEVELS ................................................................................................................................................................................ 7
BRAKE IDENTIFICATION AND ADJUSTMENT ......................................................................................................................... 8
DISASSEMBLY .......................................................................................................................................... 10
DRUM BRAKE DISASSEMBLY ................................................................................................................................................ 10
ADJUSTABLE OIL BRAKE DISASSEMBLY ............................................................................................................................. 11
NON-ADJUSTABLE OIL BRAKE DISASSEMBLY .................................................................................................................... 12
RUFNEK OIL BRAKE DISASSEMBLY ..................................................................................................................................... 13
CLUTCH AND DRUM DISASSEMBLY ..................................................................................................................................... 14
GEARBOX DISASSEMBLY ...................................................................................................................................................... 15
GEAR INSPECTION INSTRUCTIONS ..................................................................................................................................... 16
ASSEMBLY ................................................................................................................................................ 17
GEARBOX ASSEMBLY ............................................................................................................................................................ 17
DRUM BRAKE ASSEMBLY ...................................................................................................................................................... 18
ADJUSTABLE OIL BRAKE ASSEMBLY ................................................................................................................................... 19
NON-ADJUSTABLE OIL BRAKE ASSEMBLY .......................................................................................................................... 20
RUFNEK OIL BRAKE ASSEMBLY ........................................................................................................................................... 21
CLUTCH AND DRUM ASSEMBLY ........................................................................................................................................... 22
TROUBLESHOOTING ................................................................................................................................ 23
TORQUE SPECIFICATIONS CHART ........................................................................................................ 24
CLUTCH INSPECTION .............................................................................................................................. 25
BILL OF MATERIAL ......................................................................................... Error! Bookmark not defined.
ADJUSTABLE OIL BRAKE BILL OF MATERIAL .................................................................................... 29
NON ADJUSTABLE OIL BRAKE BILL OF MATERIAL ........................................................................... 29
RUFNEK OIL BRAKE BILL OF MATERIAL .............................................................................................. 30
ISOMETRIC VIEW ...................................................................................................................................... 31
SEL-0047-001.DOC
REV-4 July 2020
RUFNEK 45
AND
MODEL 64

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  • Page 1: Table Of Contents

    RUFNEK 45 MODEL 64 SERVICE MANUAL DESIGN SERIES 001 GENERAL INFORMATION .......................... 4 INTRODUCTION AND THEORY OF OPERATION ........................4 ASSEMBLY NUMBER EXPLANATION ............................4 WINCH BREAK-IN ..................................4 MODEL CODES ............................5 MAINTENANCE ............................6 OIL LEVELS ....................................7 BRAKE IDENTIFICATION AND ADJUSTMENT .........................
  • 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 and with a thorough knowledge of the equipment and its performance capabilities must be understood.
  • 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. Must stay clear of the load at all times.

  • Page 4: General Information

    GENERAL INFORMATION INTRODUCTION AND THEORY OF OPERATION The Tulsa worm gear winch is operated by turning the input of the worm using a hydraulic motor or PTO driven sprocket and chain. The winch utilizes a brake that activates only during pay-out to provide maximum efficiency during pay-in. The torque is transferred from the gearbox through the drum shaft which is keyed to a mechanically actuated sliding clutch that, when engaged, transfers the torque to the drum.

  • Page 5: Model Codes

    MODEL CODES THE RUFNEK 45 SERIES WINCHES ARE ONLY RN45 W M R F O M X AVAILABLE WITH LEFT HAND GEARS. Motor Type Gear Type 1. Single Speed Gear Motor W=Worm 2. Two Speed Gear Motor P=Planetary 3. Single Speed Geroler Motor Drive Type 4.

  • Page 6: Maintenance

    6 months of normal usage. If your winch is mounted with a drum brake, do not fill brake with oil. • Tulsa Winch recommends that the oil level in the gearbox be checked and adjusted as part of the pre-use inspection. If the oil level drops frequently or oil leakage is detected during an inspection, maintenance should be performed to correct any problems.

  • Page 7: Oil Levels

    OIL LEVELS GEARBOX FILL/VENT GEARBOX OIL LEVEL GEARBOX OIL DRAIN BRAKE FILL/VENT BRAKE OIL DRAIN BRAKE OIL LEVEL...

  • Page 8: Brake Identification And Adjustment

    BRAKE IDENTIFICATION AND ADJUSTMENT In general, worm brakes on Tulsa winches should be set to hold the load you are currently working with. Excessive brake torque will result in excessive heat generation and brake wear. The best way to insure proper brake adjustment is to pull the cable tight against the load and stop to ensure the brake holds.
  • Page 9 These brakes require no regular adjustment. 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. ______________________________________________________________________ RUFNEK ADJUSTABLE MULTIPLE DISC OIL BRAKE This brake is the Rufnek version of the adjustable oil brake.

  • Page 10: Disassembly

    DISASSEMBLY DRUM BRAKE DISASSEMBLY 1. Loosen the capscrews (78). 7. Inspect parts as follows, replace if necessary: 2. Remove the capscrews (81) from the cover (87). A. Inspect the brake shoes (86) for wear. If the shoe linings are worn 3.

  • Page 11: Adjustable Oil Brake Disassembly

    ADJUSTABLE OIL BRAKE DISASSEMBLY 1. Drain the oil from the brake by 5. Remove the spring (5). Grasp the removing the drain plug (64). brake driver (10) and remove the brake components. 2. Loosen the spring tension inside the brake turning adjusting 6.

  • Page 12: Non-Adjustable Oil Brake Disassembly

    NON-ADJUSTABLE OIL BRAKE DISASSEMBLY 1. Place a container underneath the 4. Inspect the stator plates (9), friction brake to catch the oil when the cover discs (10), and retaining ring (8) for is removed. wear and replace them if necessary. 5.

  • Page 13: Rufnek Oil Brake Disassembly

    RUFNEK OIL BRAKE DISASSEMBLY 1. Remove the bottom drain plug (25) 5. Inspect parts as follows, replace if to drain oil from brake. necessary: 2. Loosen the spring tension inside the A. Inspect the friction discs (5) for brake rotating adjusting uneven excessive...

  • Page 14: Clutch And Drum Disassembly

    CLUTCH AND DRUM DISASSEMBLY 1. Remove the rod (44) by removing 7. Remove the brake band assembly by the cotter keys (32) and pins (33). removing capscrews (31), washers (30), nuts (26) 2. Remove the arms (34) by removing attaching the brake band to the the capscrews (46), nuts (24), and frame.

  • Page 15: Gearbox Disassembly

    DISASSEMBLY GEARBOX DISASSEMBLY 1. Supporting the end of the output worm (57) out of the housing (61). shaft (68) with a hoist, remove the Remove the bearings (54). housing cover (76) by removing capscrews (3 & 46), nuts (20 & 24), and washers (19 &...

  • Page 16: Gear Inspection Instructions

    GEAR INSPECTION INSTRUCTIONS LAND 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.

  • Page 17: Assembly

    ASSEMBLY GEARBOX ASSEMBLY 1. Press the bearings (54) onto the 3. Install the keys (70) into the output worm (57) then install the worm and shaft (68). bearings into the housing (61). 4. Slide the carrier (72) onto output 2. For winches driven by a hydraulic shaft over the keys (70).

  • Page 18: Drum Brake Assembly

    DRUM BRAKE ASSEMBLY 1. Press the oil seal (55) into the brake 3. If removed, reattach the cam (88) to housing (89). Install the gasket (52), the brake cover (87) using two and attach the brake housing (89) to capscrews (78) and washers (80). the gearbox with six capscrews (56), using gasket (52).

  • Page 19: Adjustable Oil Brake Assembly

    ADJUSTABLE OIL BRAKE ASSEMBLY 1. Press the oil seal (16) into the brake 5. Attach the brake cover (19) with housing (12). Mount the brake eight capscrews (1) and washers housing with six capscrews (2), using (17), using gasket (11). gasket (22).

  • Page 20: Non-Adjustable Oil Brake Assembly

    NON-ADJUSTABLE OIL BRAKE ASSEMBLY 1. Press the oil seal (19) into the brake 4. Install the spring (5) then press the housing (1). Attach the brake washer (12) into the brake cover housing (1) with six capscrews (18), (13). using gasket (21). 5.

  • Page 21: Rufnek Oil Brake Assembly

    RUFNEK OIL BRAKE ASSEMBLY 1. Press the oil seal (27) into the brake attach the brake cover to the housing housing (14). Attach the brake (14) with eight evenly installed housing to the gearbox with eight capscrews (17) and washers (16). capscrews (15) using gasket (13).

  • Page 22: Clutch And Drum Assembly

    CLUTCH AND DRUM ASSEMBLY 1. Install bushings (60) into drum (14). 3. Install the end bracket (6) and yoke Install the drum (14) onto the output assembly or clutch position indicator shaft (68). assembly (90) onto the output shaft (68) and mount it to the frame using 2.

  • Page 23: Troubleshooting

    TROUBLESHOOTING FAILURE PROBABLE CAUSE Clutch handle won’t latch a) Clutch jaws aren’t aligned. Align the jaws by rotating drum. b) Damaged yoke or linkage. Replace the yoke or clutch Oil leaks from housing a) Seal damaged or worn. Replace the seal(s).

  • 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- *(Ft- *(Ft- *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) Lbs) Lbs) Lbs) 5/16 5/16 7/16 7/16 9/16 9/16 1019...

  • Page 25: Clutch Inspection

    CLUTCH INSPECTION...

  • Page 26: Bill Of Material

    BILL OF MATERIAL DESCRIPTION 20517 DOWEL PIN 32729 BUSHING 20886 CAPSCREW 21128 GREASE FITTING 20144 END CAP 20146 BRACKET 20129 BRACKET 1091 BRAKE BAND ASSEMBLY 20515 SET SCREW 20225 WASHER 20214 CLUTCH 23599 CLUTCH 20285 CAPSCREW 32720 DRUM 21163 U BOLT 20325 CAPSCREW 21775...
  • Page 27 OUTPUT SHAFT (FLUSH) 20221 BUSHING 20575 23884 CAPSCREW 22452 CARRIER 20569 SPACER 164056 DOWEL PIN 20789 RIGHT HAND GEAR 20790 LEFT HAND GEAR 20204 COVER (MODEL 64) 44032 COVER (RUFNEK 45) 26799 BREATHER 20522 CAPSCREW 20316 GASKET 20617 WASHER 20524 CAPSCREW...
  • Page 28 20314 20679 DRUM 20313 WASHER 20312 1108 BRAKE SHOE 20683 COVER 20685 RIGHT HAND CAM 20687 LEFT HAND CAM 20677 HOUSING 4363 CLUTCH POSITION INDICATOR KIT 40425 MOTOR (16 TOOTH INPUT) 40666 MOTOR (17 TOOTH INPUT) 20310 CAPSCREW 40424 GASKET 41285 OIL SEAL 40698...

  • Page 29: Adjustable Oil Brake Bill Of Material

    ADJUSTABLE BRAKE BILL OF MATERIAL DESCRIPTION 20289 CAPSCREW 33212 CAPSCREW 26854 STATOR PLATE 32765 FRICTION DISC 33179 BRAKE SPRING 41403 INNER RACE 31076 RETAINING RING 33407 CAM CLUTCH 41404 SPRING PLATE 41405 DRIVER 32951 GASKET 33177 BRAKE HOUSING 27215 RETAINING RING 41406 ADJUSTING MECHANISM 23900...

  • Page 30: Rufnek Oil Brake Bill Of Material

    RUFNEK BRAKE BILL OF MATERIAL DESCRIPTION 44139 COUPLER 41416 RETAINING RING 27215 RETAINING RING 26854 STATOR PLATE 32765 FRICTION DISC 33179 SPRING 44148 DRIVER 41743 BUSHING 41723 RACE 26980 RETAINING RING 41759 CLUTCH 25519 20315 GASKET 33177 BRAKE HOUSING 33212 CAPSCREW 20289 CAPSCREW...

  • Page 31: Isometric View

    ISOMETRIC VIEW FOR ADJUSTABLE OIL BRAKE AND HYDRAULIC MOTOR, SEE PAGE 32...

  • Page 32: Hydraulic Motor, Adjustable Oil Brake, & Clutch Position Indicator

    HYDRAULIC MOTOR, ADJUSTABLE OIL BRAKE, & CLUTCH POSITION INDICATOR MOTOR VIEW ADJUSTABLE OIL BRAKE CLUTCH POSITION INDICATOR KIT PO Box 1130 Jenks OK 74037-1130 USA Phone: 918-298-8300 www.dovertwg.com...

This manual is also suitable for:

Rufnek 64

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