Dover TWG TULSA RUFNEK Series Service Manual
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Dover TWG TULSA RUFNEK Series Service Manual

Dover TWG TULSA RUFNEK Series Service Manual

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INTRODUCTION AND THEORY OF OPERATION ..................................................................................... 2
ASSEMBLY NUMBER EXPLANATION ...................................................................................................... 2
WINCH MODEL CODE................................................................................................................................. 2
MAINTENANCE............................................................................................................................................ 3
GENERAL DISASSEMBLY.......................................................................................................................... 3
A. MOTOR DISASSEMBLY............................................................................................................................................................3
B. BRAKE SECTION DISASSEMBLY ............................................................................................................................................3
C. DRUM SECTION DISASSEMBLY .............................................................................................................................................3
D. GEAR SECTION DISASSEMBLY..............................................................................................................................................3
E. INPUT PLANET SET DISASSEMBLY........................................................................................................................................3
F. SECONDARY PLANET SET DISASSEMBLY............................................................................................................................3
G. OUTPUT PLANET SET DISASSEMBLY ...................................................................................................................................3
GENERAL ASSEMBLY................................................................................................................................ 3
H. OUTPUT PLANET SET ASSEMBLY .........................................................................................................................................3
I. SECONDARY PLANET SET ASSEMBLY ...................................................................................................................................3
J. INPUT PLANET SET ASSEMBLY ..............................................................................................................................................3
K. GEAR END ASSEMBLY ............................................................................................................................................................3
L. DRUM SECTION ASSEMBLY....................................................................................................................................................3
M. BRAKE SECTION ASSEMBLY .................................................................................................................................................3
N. MOTOR ASSEMBLY .................................................................................................................................................................3
TROUBLESHOOTING.................................................................................................................................. 3
RUFNEK 60 BILL OF MATERIAL ............................................................................................................... 3
VISCOSITY CHART ..................................................................................................................................... 3
TORQUE SPECIFICATIONS CHART.......................................................................................................... 3
RUFNEK 60 ISOMETRIC DRAWING .......................................................................................................... 3
SEL-0039-004.DOC
REV-0
RUFNEK 60
SERVICE MANUAL
DESIGN SERIES 004

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Summary of Contents for Dover TWG TULSA RUFNEK Series

  • Page 1 DESIGN SERIES 004 RUFNEK 60 SERVICE MANUAL INTRODUCTION AND THEORY OF OPERATION ..................2 ASSEMBLY NUMBER EXPLANATION ...................... 2 WINCH MODEL CODE..........................2 MAINTENANCE............................3 GENERAL DISASSEMBLY.......................... 3 A. MOTOR DISASSEMBLY................................3 B. BRAKE SECTION DISASSEMBLY ............................3 C. DRUM SECTION DISASSEMBLY .............................3 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 brake cover from the counterbalance block (76) and (2). inspect the metering hole to make sure it is not obstructed.
  • Page 7 B. BRAKE SECTION DISASSEMBLY 1. Evenly remove the four cap screws (3) that plate for scoring caused by the removal of hold the brake cover (2) in place. Spring the piston and polish if necessary. Friction pressure will raise the cover up as the cover discs should measure no less than .055-in.
  • Page 8 C. DRUM SECTION DISASSEMBLY 1. To remove the drum, first disconnect the cylinder. You can now remove the brake cable from the U-bolt (35) and lay aside. If band assembly (66). Note which frame the removing the drum from the motor end with mounting bolts are on for re-assembly.
  • Page 9 CLUTCH INSPECTION...
  • Page 10 D. GEAR SECTION DISASSEMBLY 1. Drain the oil by removing the plug (85). 6. Remove the secondary gear set (41) and sun gear (45). Inspect and replace if 2. To disassemble the gear section, remove necessary. the Intelliguard™ sensor (39) from the outer cover (55) by removing three capscrews 7.
  • Page 11 E. INPUT PLANET SET DISASSEMBLY 1. Remove the retaining rings (42-4) from the 3. Remove the planet gears (42-2), thrust planet pins (42-3). washers (42-6) and bearings (42-5) from the carrier. 2. Remove the pins (42-3) from the carrier (42-1) by carefully tapping them out. 4.
  • Page 12 F. SECONDARY PLANET SET DISASSEMBLY 1. Remove the retaining rings (41-4) from the 3. Remove the planet gears (41-2), thrust planet pins (41-5). washers (41-6) and bearings (41-3) from the carrier. 2. Remove the pins (41-5) from the carrier (41-1) by carefully tapping them out. 4.
  • Page 13 G. OUTPUT PLANET SET DISASSEMBLY 1. Remove the retaining rings (40-4) from the 4. Remove the thrust plate (40-5) and snap planet pins (40-3). ring (40-9) from the carrier. 2. Remove the pins (40-3) from the carrier 5. Inspect the parts for wear or damage and (40-1) by carefully tapping them out replace if necessary.

  • Page 14: General Assembly

    GENERAL ASSEMBLY H. OUTPUT PLANET SET ASSEMBLY 1. Insert the snap ring (40-9) and the thrust 2. Being careful to line up the thrust washers plate (40-5) into the carrier (40-2) along with (40-8) and bearings (40-6) with the planet the gears (40-2), bearings (40-6), spacers pins (40-3), press the pins into the carrier.
  • Page 15 I. SECONDARY PLANET SET ASSEMBLY 1. Insert the thrust plate (41-7) into the carrier 2. Being careful to line up the thrust washers (41-4) along with the gears (41-2), bearings (41-6) and bearings (41-3) with the planet (41-3), and thrust washers (41-6). pins (41-5), press the pins into the carrier.
  • Page 16 J. INPUT PLANET SET ASSEMBLY 1. Insert the thrust plate (42-7) into the carrier 2. Being careful to line up the thrust washers (42-1) along with the gears (42-1), bearings (42-6) and bearings (42-5) with the planet (42-5), and thrust washers (42-6). pins (42-3), press the pins into the carrier.
  • Page 17 K. GEAR END ASSEMBLY 1. Bolt the gear-housing (60) loosely into both 4. Install the sun gear (47), and the output sun frames (65, 64). Slide the output shaft (38) gear (46). Then install the secondary gear halfway into the gear housing (60). set (41) into the gear housing (60).
  • Page 18 L. DRUM SECTION ASSEMBLY 1. After inspecting and replacing the necessary 3. If necessary, install the new drum clutch (28) parts, install the drum (34) onto the output using six capscrews (33). Torque to shaft (38). This part is very heavy and you specified torque (see page 29 of this will need the assistance of a hoist.
  • Page 19 DRUM SECTION ASSEMBLY CONTINUED 5. Slide the brake housing (20) onto the output 9. If necessary, install the air cylinder (105) shaft. and the air cylinder cover (91) to the brake housing with four capscrews (69) and 6. Bolt the brake housing (20) loosely into both spacers (97).
  • Page 20 M. BRAKE SECTION ASSEMBLY 1. Re-assemble the driver/clutch assembly making sure the clutch is installed properly and checking to make sure the cam clutch is Dip friction discs in lightweight free turning in the pay in direction. Non-EP oil before installation. 2.
  • Page 21 BRAKE SECTION ASSEMBLY CONTINUED 7. Install the o-ring (6) onto the brake cover by applying 100psi to the brake port and and install the cover (2) onto the brake adapting a torque wrench to the input shaft. housing (20) using four cap screws (3). The torque in the payout should be 157 to Then draw it down evenly, alternating 177 ft-lbs.
  • Page 22 N. MOTOR ASSEMBLY 1. Install the o-ring (98) onto the motor (1) and 4. Install the o-ring (107) into the manifold install the motor using four capscrews (88). block (93) and counterbalance block (76). Tighten the capscrews to the proper torque Install the manifold block (93) and counter- specification (see page 29 of this manual).

  • 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 60 BILL OF MATERIAL 81866004-BOM MAY 2006 ITEM DESCRIPTION 43152 HYDRAULIC MOTOR 43419 BRAKE COVER 28060 CAPSCREW 42494 HOSE ASSEMBLY 42942 BRAKE PISTON 33094 O-RING 42230 BRAKE SPRING 32186 O-RING 42337 RING 42335 O-RING 42336 BACK-UP RING 42148 STATOR PLATE 32765 FRICTION DISC 44335...
  • Page 25 RUFNEK 60 BILL OF MATERIAL CONTINUED 40-1 43012 OUTPUT CARRIER 40-2 43015 OUTPUT PLANET GEAR 40-3 41747 PLANET PIN 40-4 41716 RETAINING RING 40-5 43701 PLATE 40-6 41717 BEARING 40-7 41739 SPACER 40-8 939249 RACE 40-9 27011 SNAP RING 4235 SECONDARY GEARSET 41-1 43013...
  • Page 26 RUFNEK 60 BILL OF MATERIAL CONTINUED 30203 CAPSCREW 20318 20559 LOCKWASHER 43077 RIGHT FRAME 43076 LEFT FRAME 4238 BRAKE BAND ASSEMBLY 43882 CLUTCH YOKE 42929 BRAKE BAND AIR CYLINDER 43880 CAPSCREW 20525 CAPSCREW 20521 20518 LOCKWASHER 42955 MOUNTING BRACKET 42978 O-RING PLUG 13050 BREATHER...
  • Page 27 RUFNEK 60 BILL OF MATERIAL CONTINUED OMIT 44340 AIR CYLINDER 43372 CAPSCREW 32182 O-RING 41867 COUNTERBALANCE VALVE 44756 INTELLIGUARD LOGO PLATE OMIT 994188 THRUST RACE 33324 WASHER OMIT...

  • Page 28: Viscosity Chart

    VISCOSITY CHART...

  • Page 29: 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 30 RUFNEK 60 ISOMETRIC DRAWING 41-4 41-5 41-6 41-3 41-2 41-3 41-6 40-5 40-9 41-1 41-7 40-4 40-3 40-8 40-6 40-2 40-7 40-6 40-8 42-4 DO NOT USE MAGNETS 42-3 ON OR AROUND WINCH. 42-6 42-5 40-1 42-2 40-9 42-6 40-5 42-1 42-7 PO Box 1130...

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