Dover TWG design 004 Series Service Manual
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Dover TWG design 004 Series Service Manual

Dover TWG design 004 Series Service Manual

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INTRODUCTION AND THEORY OF OPERATION ..................................................................................... 2
ASSEMBLY NUMBER EXPLANATION ...................................................................................................... 2
WINCH MODEL CODE................................................................................................................................. 2
MAINTENANCE............................................................................................................................................ 5
GENERAL DISASSEMBLY.......................................................................................................................... 6
A. MOTOR DISASSEMBLY................................................................................................................................................................6
B. BRAKE SECTION DISASSEMBLY ................................................................................................................................................7
C. DRUM SECTION DISASSEMBLY .................................................................................................................................................9
D. GEAR SECTION DISASSEMBLY................................................................................................................................................11
E. INPUT PLANET SET DISASSEMBLY..........................................................................................................................................12
F. SECONDARY PLANET SET DISASSEMBLY..............................................................................................................................13
G. OUTPUT PLANET SET DISASSEMBLY .....................................................................................................................................14
GENERAL ASSEMBLY.............................................................................................................................. 15
H. OUTPUT PLANET SET ASSEMBLY ...........................................................................................................................................15
I. SECONDARY PLANET SET ASSEMBLY .....................................................................................................................................16
J. INPUT PLANET SET ASSEMBLY ................................................................................................................................................17
K. GEAR END ASSEMBLY ..............................................................................................................................................................18
L. DRUM SECTION ASSEMBLY......................................................................................................................................................19
M. BRAKE SECTION ASSEMBLY ...................................................................................................................................................21
N. MOTOR ASSEMBLY ...................................................................................................................................................................22
TROUBLESHOOTING................................................................................................................................ 23
RUFNEK 100 BILL OF MATERIAL ........................................................................................................... 24
VISCOSITY CHART ................................................................................................................................... 27
TORQUE SPECIFICATIONS CHART........................................................................................................ 28
RUFNEK 100 ISOMETRIC DRAWING ...................................................................................................... 29
SEL-0040-004.DOC
REV-0
RUFNEK 100
SERVICE MANUAL
DESIGN SERIES 004

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Summary of Contents for Dover TWG design 004 Series

  • Page 1: Table Of Contents

    DESIGN SERIES 004 RUFNEK 100 SERVICE MANUAL INTRODUCTION AND THEORY OF OPERATION ..................2 ASSEMBLY NUMBER EXPLANATION ...................... 2 WINCH MODEL CODE..........................2 MAINTENANCE............................5 GENERAL DISASSEMBLY.......................... 6 A. MOTOR DISASSEMBLY................................6 B. BRAKE SECTION DISASSEMBLY ..............................7 C. DRUM SECTION DISASSEMBLY ..............................9 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 (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.

  • Page 7: Brake Section Disassembly

    B. BRAKE SECTION DISASSEMBLY 1. Evenly remove the four cap screws (60) holes in the top of the piston and run in that hold the brake cover (18) in place. evenly until the piston is clear of the Spring pressure will raise the cover up as housing.
  • Page 8 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 top stator plate for scoring caused by the removal of the piston and polish if Notice the direction of lock-up...

  • Page 9: Drum Section Disassembly

    C. DRUM SECTION DISASSEMBLY 1. To remove the drum, first disconnect the cylinder. You can now remove the brake cable from the U-bolt (43) and lay aside. If band assembly (77). Note which frame the removing the drum from the motor end with mounting bolts are on for re-assembly.
  • Page 10 CLUTCH INSPECTION...

  • Page 11: Gear Section Disassembly

    D. GEAR SECTION DISASSEMBLY 1. Drain the oil by removing the plug (86) 6. Remove secondary gear set (23) and sun located on the bottom of the end cover (3). gear (7). Inspect and replace if necessary. 2. To disassemble the gear section, remove 7.

  • Page 12: Input Planet Set Disassembly

    E. INPUT PLANET 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.

  • Page 13: Secondary Planet Set Disassembly

    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.

  • Page 14: Output Planet Set Disassembly

    G. OUTPUT PLANET SET DISASSEMBLY 1. Remove the retaining rings (24-4) from the 4. Remove the thrust plate (24-7) and the planet pins (24-5). retaining ring (24-8) from the carrier. 2. Remove the pins (24-5) from the carrier 5. Inspect the parts for wear or damage and (24-1) by carefully tapping them out replace if necessary.

  • Page 15: General Assembly

    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), and thrust pins (24-5), press the pins into the carrier.

  • Page 16: Secondary Planet Set Assembly

    I. 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.

  • Page 17: Input Planet Set Assembly

    J. INPUT PLANET SET ASSEMBLY 1. Insert the thrust plate (22-7) into the carrier 2. Being careful to line up the thrust washers (22-1) along with the gears (22-2), bearings (22-6) and bearings (22-3) with the planet (22-3), and thrust washers (22-6). pins (22-5), press the pins into the carrier.

  • Page 18: Gear End Assembly

    K. GEAR END ASSEMBLY 1. Bolt the gear housing (10) loosely into 5. Install the secondary sun gear (7). Making both frames (73, 74). Slide the output sure it’s against the washer in the secondary shaft (20) halfway into the gear housing gear set (23).

  • Page 19: Drum Section Assembly

    L. DRUM SECTION ASSEMBLY 1. After inspecting and replacing the necessary Tighten the adjusting nut on the air cylinder parts, such as the drum bushings (19), shaft until there is not space between the install the drum (11) onto the output shaft drum (11) and the brake band (77).
  • Page 20 DRUM SECTION ASSEMBLY CONTINUED 5. Install the outer thrust collar (48), aligning 9. Turn the drum to make sure it is not binding. the half moon slots with the keys (47). Tightly hold the thrust collar against the keys 10. If necessary, install the air cylinder (15) and and lock down the three set screws (89).

  • Page 21: Brake Section Assembly

    M. BRAKE SECTION ASSEMBLY 5. Install the driver/clutch assembly onto the input shaft (21). 6. 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.

  • Page 22: Motor Assembly

    N. MOTOR ASSEMBLY 1. Install the o-ring (62) onto the motor (63) 4. Install the o-ring (26) into the manifold block and install the motor using four capscrews (78) and counterbalance block (79). Install (30). Tighten the capscrews to the proper the manifold block (78) and counter-balance torque specification (see page 28 of this block (79) using four capscrews (25).

  • Page 23: Troubleshooting

    TROUBLESHOOTING FAILURE PROBABLE CAUSE Winch won’t hold load. a) Excessive backpressure 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 24: Rufnek 100 Bill Of Material

    RUFNEK 100 BILL OF MATERIAL 81867004-BOM-AUGUST 2005 ITEM DESCRIPTION 42031 HOSE ASSEMBLY 42438 STRAIGHT THREAD BRANCH TREE 44750 END COVER 42030 HOSE ASSEMBLY 41838 STRAIGHT ADAPTER 32477 CAPSCREW 42913 SECONDARY SUN GEAR 42914 OUTPUT SUN GEAR 42915 PRIMARY GEAR HOUSING 42916 GEAR HOUSING 42917...
  • Page 25 RUFNEK 100 BILL OF MATERIAL CONTINUED 24-7 42957 THRUST PLATE 24-8 43699 RETAINING RING 43372 CAPSCREW 32182 O-RING OMIT 41867 COUNTERBALANCE VALVE 32411 HEX PLUG 20524 CAPSCREW 41719 O-RING PLUG 42137 CAPLUG 28947 O-RING 42934 THRUST WASHER 28212 CAPSCREW 32368 O-RING 42935 THRUST WASHER...
  • Page 26 RUFNEK 100 BILL OF MATERIAL CONTINUED 44335 BRAKE DRIVER 20650 CAPSCREW 20653 20652 LOCKWASHER 44048 RIGHT HAND FRAME 44049 LEFT HAND FRAME 43367 CARTRIDGE VALVE 42929 BRAKE BAND AIR CYLINDER 4343 BRAKE BAND ASSEMBLY 43368 MANIFOLD BLOCK 42029 COUNTERBALANCE BLOCK 42089 90º...

  • Page 27: Viscosity Chart

    VISCOSITY CHART...

  • Page 28: 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 29: Rufnek 100 Isometric Drawing

    RUFNEK 100 ISOMETRIC DRAWING 22-5 22-6 22-3 22-6 24-7 24-8 23-4 23-5 23-6 22-4 23-3 22-1 23-6 22-7 22-2 23-1 23-7 23-2 24-4 24-5 DO NOT USE MAGNETS 24-6 24-3 ON OR AROUND WINCH. 24-6 24-1 24-8 24-7 110 106 24-2 PO Box 1130 Jenks OK 74037-1130 USA...

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Rufnek seriesRufnek 100

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