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Tulsa Rufnek Intelliguard 80 Service Manual

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INTRODUCTION AND THEORY OF OPERATION ..................................................................................... 2
ASSEMBLY NUMBER EXPLANATION ...................................................................................................... 2
WINCH MODEL CODES .............................................................................................................................. 2
MAINTENANCE............................................................................................................................................ 5
GENERAL DISASSEMBLY.......................................................................................................................... 6
A. MOTOR DISASSEMBLY................................................................................................................................................................6
B. BRAKE SECTION DISASSEMBLY ................................................................................................................................................7
C. DRUM SECTION DISASSEMBLY .................................................................................................................................................8
D. GEAR SECTION DISASSEMBLY................................................................................................................................................10
E. INPUT PLANET SET DISASSEMBLY..........................................................................................................................................11
F. SECONDARY PLANET SET DISASSEMBLY..............................................................................................................................12
G. OUTPUT PLANET SET DISASSEMBLY .....................................................................................................................................13
GENERAL ASSEMBLY.............................................................................................................................. 14
H. OUTPUT PLANET SET ASSEMBLY ...........................................................................................................................................14
I. SECONDARY PLANET SET ASSEMBLY .....................................................................................................................................15
J. INPUT PLANET SET ASSEMBLY ................................................................................................................................................16
K. GEAR END ASSEMBLY ..............................................................................................................................................................17
L. DRUM SECTION ASSEMBLY ......................................................................................................................................................18
M. BRAKE SECTION ASSEMBLY ...................................................................................................................................................20
N. MOTOR ASSEMBLY ...................................................................................................................................................................21
TROUBLESHOOTING................................................................................................................................ 22
RUFNEK 80 BILL OF MATERIAL ............................................................................................................. 23
VISCOSITY CHART ................................................................................................................................... 26
TORQUE SPECIFICATIONS CHART........................................................................................................ 27
RUFNEK 80 ISOMETRIC DRAWING ........................................................................................................ 28
SEL-0041-006.DOC
REV-0
RUFNEK 80
SERVICE MANUAL
DESIGN SERIES 006

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Summary of Contents for Tulsa Rufnek Intelliguard 80

  • Page 1: Table Of Contents

    DESIGN SERIES 006 RUFNEK 80 SERVICE MANUAL INTRODUCTION AND THEORY OF OPERATION ..................2 ASSEMBLY NUMBER EXPLANATION ...................... 2 WINCH MODEL CODES ..........................2 MAINTENANCE............................5 GENERAL DISASSEMBLY.......................... 6 A. MOTOR DISASSEMBLY................................6 B. BRAKE SECTION DISASSEMBLY ..............................7 C. DRUM SECTION DISASSEMBLY ..............................8 D.

  • Page 2: 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 3 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 4 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 5: Maintenance

    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. 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.

  • Page 6: General Disassembly

    GENERAL DISASSEMBLY A. MOTOR DISASSEMBLY 1. Drain the oil from the brake assembly by 5. Remove the counterbalance valve (108) removing the plug (81) from the bottom of from the counterbalance block (76) and the brake cover (2). inspect the metering hole to make sure it is not obstructed.

  • Page 7: Brake Section Disassembly

    B. BRAKE SECTION DISASSEMBLY 1. Evenly remove the four cap screws (3) that the piston and polish if needed. Friction hold the brake cover (2) in place. Spring discs should measure no less than .055-in. pressure will raise the cover up as the cap thickness and stator plates should measure screws are loosened.

  • Page 8: Drum Section Disassembly

    C. DRUM SECTION DISASSEMBLY 1. With the motor and brake disassembled, first Remove the brake band assembly (66) by remove the cotter keys (100) and clevis pins removing two cap screws (70), nuts and (49) connecting the yoke (67) to the bracket washers (71, 72) from the frames (64 or 65).
  • Page 9 CLUTCH INSPECTION...

  • Page 10: Gear Section Disassembly

    D. GEAR SECTION DISASSEMBLY 1. Drain the oil by removing the plug (85) 6. Remove the sun gear (45) and secondary located on the bottom of the adapter cover gear set (41). Inspect and replace if (58). necessary. 2. To disassemble the gear section, remove 7.

  • Page 11: Input Planet Set Disassembly

    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.

  • Page 12: Secondary Planet Set Disassembly

    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.

  • Page 13: Output Planet Set Disassembly

    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.

  • Page 14: General Assembly

    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).

  • Page 15: Secondary Planet Set Assembly

    I. SECONDARY PLANET SET ASSEMBLY 1. 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.

  • Page 16: Input Planet Set Assembly

    J. 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.

  • Page 17: Gear End Assembly

    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.

  • Page 18: Drum Section Assembly

    L. DRUM SECTION ASSEMBLY 1. After inspecting and replacing the necessary (34) and the brake band (66). Then, tighten parts, such as the drum bushings (31), drum the jam nut to secure the adjusting nut. clutch (115). Install the drum (34) onto the output shaft (38).
  • Page 19 DRUM SECTION ASSEMBLY CONTINUED 7. Bolt the brake housing (20) loosely into both housing with four capscrews (69) and frames (64, 65). Lower the drum so the spacers (97). weight of the drum is supported by both the brake and gear housings. The air line from 11.

  • Page 20: Brake Section Assembly

    M. BRAKE SECTION ASSEMBLY 1. Re-assemble the driver/clutch assembly 6. Install the springs (7) into the spring pockets making sure the clutch is installed properly in the piston. If working in a horizontal and checking to make sure the cam clutch is position, coat the bottom of each spring with free turning in the pay in direction.

  • Page 21: Motor Assembly

    N. MOTOR ASSEMBLY 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 proper torque (106). specification (see page 27 of this manual). 6.

  • Page 22: Troubleshooting

    TROUBLESHOOTING FAILURE PROBABLE CAUSE Winch won’t hold load. a) Excessive back pressure in the system. Check the system for restrictions and reduce the backpressure. b) Brake discs are worn out. Replace brake discs. c) Winch clutch is slipping. Inspect the clutch and driver for wear and replace worn parts.

  • Page 23: Rufnek 80 Bill Of Material

    RUFNEK 80 BILL OF MATERIAL DESCRIPTION 43152 HYDRAULIC MOTOR 43419 BRAKE COVER 28060 CAP SCREW 42494 HOSE ASSEMBLY 42942 BRAKE PISTON 33094 O-RING 42230 BRAKE SPRING 32186 O-RING 42337 BACK-UP RING 42335 O-RING 42336 BACK-UP RING 42148 STATOR PLATE 32765 FRICTION DISC 44335 BRAKE DRIVER...
  • Page 24 RUFNEK 80 BILL OF MATERIAL CONTINUED DESCRIPTION 32477 CAPSCREW 44430 SECONDARY SUN GEAR 44431 OUTPUT SUN GEAR 43699 RETAINING RING 43828 CLEVIS 43827 CLEVIS PIN 21653 SET SCREW 21128 ZERK GREASE FITTING 42932 BALL BEARING 43696 THRUST COLLAR 43459 HOSE ASSEMBLY 44736 COVER 42495...
  • Page 25 RUFNEK 80 BILL OF MATERIAL CONTINUED DESCRIPTION 20524 CAPSCREW 32411 HEX PLUG 43877 CLUTCH BRACKET 43835 AIR CYLINDER COVER 42089 90º ADAPTER 43368 MANIFOLD BLOCK 44436 SHAFT KEY 43078 SPACER 34003 O-RING 939243 CLEVIS PIN 20514 COTTER PIN 43367 12 VOLT CARTRIDGE VALVE 44340 AIR CYLINDER 43372...

  • Page 26: Viscosity Chart

    VISCOSITY CHART...

  • Page 27: 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 28: Rufnek 80 Isometric Drawing

    RUFNEK 80 ISOMETRIC DRAWING DO NOT USE MAGNETS ON OR AROUND WINCH. PO Box 1130 Jenks OK 74037-1130 USA Phone: 918-298-8300 www.dovertwg.com...

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