Dover TWG Tulsa RUFNEK 80 DESIGN 001 Series Service Manual
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Dover TWG Tulsa RUFNEK 80 DESIGN 001 Series Service Manual

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SERVICE MANUAL
INTRODUCTION AND THEORY OF OPERATION ..................................................................................... 2
ASSEMBLY NUMBER EXPLANATION ...................................................................................................... 2
WINCH MODEL CODES .............................................................................................................................. 2
!WARNING! .................................................................................................................................................. 3
MAINTENANCE............................................................................................................................................ 4
GENERAL DISASSEMBLY.......................................................................................................................... 5
A. MOTOR DISASSEMBLY....................................................................................................................... 5
B. BRAKE SECTION DISASSEMBLY ....................................................................................................... 6
C. DRUM SECTION DISASSEMBLY ........................................................................................................ 7
D. GEAR SECTION DISASSEMBLY......................................................................................................... 8
E. INPUT PLANET SET DISASSEMBLY................................................................................................... 9
F. SECONDARY PLANET SET DISASSEMBLY..................................................................................... 10
G. OUTPUT PLANET SET DISASSEMBLY ............................................................................................ 11
GENERAL ASSEMBLY.............................................................................................................................. 12
H. OUTPUT PLANET SET ASSEMBLY .................................................................................................. 12
I. SECONDARY PLANET SET ASSEMBLY ............................................................................................ 13
J. INPUT PLANET SET ASSEMBLY ....................................................................................................... 14
K. GEAR END ASSEMBLY...................................................................................................................... 15
L. DRUM SECTION ASSEMBLY............................................................................................................. 16
M. BRAKE SECTION ASSEMBLY .......................................................................................................... 17
N. MOTOR ASSEMBLY........................................................................................................................... 18
TROUBLESHOOTING................................................................................................................................ 20
RUFNEK 80 BILL OF MATERIAL ............................................................................................................. 21
VISCOSITY CHART ................................................................................................................................... 24
TORQUE SPECIFICATIONS CHART........................................................................................................ 25
RUFNEK 80 ISOMETRIC DRAWING ........................................................................................................ 26
SEL-0041-001.DOC
REV-0
RUFNEK 80
DESIGN SERIES 001

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Summary of Contents for Dover TWG Tulsa RUFNEK 80 DESIGN 001 Series

  • Page 1: Table Of Contents

    RUFNEK 80 DESIGN SERIES 001 SERVICE MANUAL INTRODUCTION AND THEORY OF OPERATION ..................2 ASSEMBLY NUMBER EXPLANATION ...................... 2 WINCH MODEL CODES ..........................2 !WARNING! ..............................3 MAINTENANCE............................4 GENERAL DISASSEMBLY.......................... 5 A. MOTOR DISASSEMBLY........................5 B. BRAKE SECTION DISASSEMBLY ....................... 6 C.

  • 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: Warning

    !WARNING! FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH. 1. Tulsa Winches are not to be used to lift, hoist, or move people. If your task involves lifting or moving people, you MUST use the proper equipment, not this winch. 2.

  • Page 4: 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 5: 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 6: Brake Section Disassembly

    B. BRAKE SECTION DISASSEMBLY 1. Evenly remove the four cap screws (3) that them for excessive wear. Replace the parts hold the brake cover (2) in place. Spring if necessary. Be sure to check the top stator pressure will raise the cover up as the cap plate for scoring caused by the removal of screws are loosened.

  • Page 7: Drum Section Disassembly

    C. DRUM SECTION DISASSEMBLY 1. To remove the drum, first disconnect the shaft (38). At this time you will need to cable from the cable clamp (35) and lay remove the two cap screws (70), nuts and aside. If removing the drum from the motor washers (71, 72) from the frames (64 or 65).

  • Page 8: Gear Section Disassembly

    D. GEAR SECTION DISASSEMBLY 1. Drain the oil by removing the plug (85) 7. Remove the gear ring (22) by removing the located on the bottom of the adapter cover two cap screws (111). Inspect the o-ring (58). (57) and replace if necessary. 2.

  • Page 9: 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 10: 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 11: 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 12: General Assembly

    GENERAL ASSEMBLY H. OUTPUT PLANET SET ASSEMBLY 1. Insert the gears (2), bearings (6), spacers press the pins into the carrier. If the pins are (5) and thrust washers (3) into the carrier not lined up properly, the thrust washer can (1).

  • Page 13: Secondary Planet Set Assembly

    I. SECONDARY PLANET SET ASSEMBLY 1. Insert the gears (6), bearings (4), spacers press the pins into the carrier. If the pins are (5), and thrust washers (3) into the carrier not lined up properly, the thrust washer can (1). be shattered during the pressing operation.

  • Page 14: Input Planet Set Assembly

    J. INPUT PLANET SET ASSEMBLY 1. Insert the gears (4), bearings (5) and thrust are not lined up properly, the thrust washer washers (3) into the carrier (1). can be shattered during the pressing operation. 2. Being careful to line up the thrust washers (3) and bearings (5) with the planet pins (2), 3.

  • Page 15: Gear End Assembly

    K. GEAR END ASSEMBLY 1. Bolt gear-housing (60) loosely into both Make sure to line up all three planet gears in frames (64, 65). secondary gear set with the gear housing and sun gear as it starts into the housing.) 2.

  • Page 16: Drum Section Assembly

    L. DRUM SECTION ASSEMBLY 1. After inspecting and replacing the necessary the three keys (94) into their slots in the parts, such as the drum bushings (31). output shaft. Install the drum (34) onto the output shaft (38). This part is very heavy and you will 4.

  • Page 17: Brake Section Assembly

    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 18 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 19: 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). (Note: Make sure you install the motor with 6.

  • Page 20: 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 21: Rufnek 80 Bill Of Material

    RUFNEK 80 BILL OF MATERIAL DESCRIPTION 43399 HYDRAULIC MOTOR 43419 BRAKE COVER 28060 CAPSCREW 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 29162...
  • Page 22 RUFNEK 80 BILL OF MATERIAL CONTINUED DESCRIPTION 44429 INPUT SUN GEAR 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 44462...
  • Page 23 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 OMIT OMIT 43078 SPACER 34003 O-RING 939243 CLEVIS PIN 20514 COTTER PIN 43367 12 VOLT CARTRIDGE VALVE 43879...

  • Page 24: Viscosity Chart

    VISCOSITY CHART...

  • Page 25: 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 26: Rufnek 80 Isometric Drawing

    RUFNEK 80 ISOMETRIC DRAWING PO Box 1130 Jenks OK 74037-1130 USA Phone: 918-298-8300 www.dovertwg.com...

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