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Tulsa Rufnek Intelliguard 45, Service Manual

The Tulsa Rufnek Intelliguard 45 Service Manual is a comprehensive guide for users of this cutting-edge security system. This manual provides step-by-step instructions, troubleshooting tips, and valuable insights to ensure seamless installation and optimal performance. Download your free copy from our website and master the full potential of your Intelliguard 45.

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SEL-0034-003.DOC 
REV-0 

            

            RUFNEK 45 

 

                 SERVICE MANUAL 

 

 
 
 
 

 

INTRODUCTION AND THEORY OF OPERATION ............................................................................2

 

ASSEMBLY NUMBER EXPLANATION..............................................................................................2

 

WINCH MODEL CODES ......................................................................................................................2

 

!WARNING! ...........................................................................................................................................3

 

MAINTENANCE ....................................................................................................................................5

 

GENERAL DISASSEMBLY .................................................................................................................6 

 

A.

 

MOTOR

 

DISASSEMBLY ................................................................................................................................................... 7

 

B.

 

BRAKE

 

SECTION

 

DISASSEMBLY ................................................................................................................................... 7

 

C.

 

DRUM

 

SECTION

 

DISASSEMBLY..................................................................................................................................... 8

 

D.

 

GEAR

 

SECTION

 

DISASSEMBLY ................................................................................................................................... 10

 

E.

 

INPUT

 

PLANET

 

SET

 

DISASSEMBLY ............................................................................................................................. 11

 

F.

 

OUTPUT

 

PLANET

 

SET

 

DISASSEMBLY ......................................................................................................................... 12 

 

GENERAL ASSEMBLY......................................................................................................................13 

 

G.

 

OUTPUT

 

PLANET

 

SET

 

ASSEMBLY............................................................................................................................... 13

 

H.

 

INPUT

 

PLANET

 

SET

 

ASSEMBLY ................................................................................................................................... 14

 

I.

 

GEAR

 

END

 

ASSEMBLY.................................................................................................................................................... 15

 

J.

 

DRUM

 

SECTION

 

ASSEMBLY.......................................................................................................................................... 16

 

K.

 

BRAKE

 

SECTION

 

ASSEMBLY........................................................................................................................................ 17

 

L.

 

MOTOR

 

ASSEMBLY ........................................................................................................................................................ 18 

 

TROUBLESHOOTING........................................................................................................................19

 

RUFNEK 45 BILL OF MATERIAL .....................................................................................................20

 

VISCOSITY CHART............................................................................................................................23

 

TORQUE SPECIFICATIONS CHART................................................................................................24

 

RUFNEK 45 ISOMETRIC DRAWING ................................................................................................25

 

 

 

DESIGN SERIES 003 

Summary of Contents for Rufnek Intelliguard 45

Page 1: ...TION DISASSEMBLY 8 D GEAR SECTION DISASSEMBLY 10 E INPUT PLANET SET DISASSEMBLY 11 F OUTPUT PLANET SET DISASSEMBLY 12 GENERAL ASSEMBLY 13 G OUTPUT PLANET SET ASSEMBLY 13 H INPUT PLANET SET ASSEMBLY 14 I GEAR END ASSEMBLY 15 J DRUM SECTION ASSEMBLY 16 K BRAKE SECTION ASSEMBLY 17 L MOTOR ASSEMBLY 18 TROUBLESHOOTING 19 RUFNEK 45 BILL OF MATERIAL 20 VISCOSITY CHART 23 TORQUE SPECIFICATIONS CHART 24 RU...

Page 2: ...he brake fully open at about 340 PSI the brake valve will open and dynamically control the lowering of the load ASSEMBLY NUMBER EXPLANATION This manual is for design series 003 In the case of a major design change implementation a new design series designation number will be issued for the winch A new manual will also be created for that specific design series WINCH MODEL CODES Gear Type W Worm P ...

Page 3: ... approved by a qualified person All welding should also be done by a qualified person Winch mount must be flat so as not to induce binding The flatness must not exceed 1 16 inch across the mounting surface of the winch itself Guards must be placed on all open drives in the case of mechanical winches Insure that all hydraulic hoses valves and fittings are rated to winch manufacturer s operating pre...

Page 4: ... for compliance Must insure that the drum clutch is fully engaged before hoisting A visual inspection of the drum clutch engagement is required before each winching operation Must rig all loads secure before winching Pull the load line taut and inspect the condition of load for stability Must inspect the drum brake if equipped The drum brake is not a load holding device it is design to prevent ove...

Page 5: ...is winch is mounted to is subject to standards for this type of inspection then those standards must be followed If oil changes reveal significant metallic particles then a teardown and inspection must be made to determine the source of wear Rufnek series planetary winches are designed with a common oil reservoir for the gearbox and brake The winches are shipped from the factory filled with Mobilu...

Page 6: ...the winch by removing four capscrews 88 5 Remove the counterbalance valve 50 from the counterbalance block 32 and inspect the metering hole to make sure it is not obstructed Also inspect the o rings on valve to insure that they are not flat or cut Replace if necessary 6 Motors and counterbalance valves are not serviceable in the field Return them to an authorized dealer for service 7 Inspect the o...

Page 7: ... plates 12 and friction discs 13 from the brake housing and 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 necessary Friction discs should measure no less than 0 055 in thick and stator plates should measure no less than 0 068 in thick 6 To disassemble the brake driver clutch assembly remove...

Page 8: ...ft 40 9 At this time you will need to remove two capscrews 70 nuts and washers 72 71 from the frames 64 65 Do not remove air cylinder 68 yet You can now remove the brake band assembly 66 Note which frame the mounting bolts are on for re assembly Inspect and replace if needed 3 Remove the outer thrust collar 105 by loosening three set screws 89 4 Remove the yoke 87 sliding clutch 27 and coupler 30 ...

Page 9: ...9 CLUTCH INSPECTION ...

Page 10: ... 44 Inspect the gear teeth on the Intelliguard 23 for wear The Intelliguard system is not serviceable in the field Return to an authorized dealer for service 3 Remove the end cover 55 by removing eight capscrews 21 4 Inspect the o rings 36 59 for wear and replace if necessary 5 Remove the input gear set 41 along with the inner and outer thrust washers 43 Inspect and replace if necessary 6 Remove t...

Page 11: ...net pins 41 6 Remove the pins from the carrier 41 1 by carefully tapping them out 2 Remove the planet gears 41 3 thrust washers 41 4 and bearings 41 2 from the carrier 41 1 3 With planet gears out remove the plate 41 7 4 Inspect the parts for wear or damage and replace if necessary ...

Page 12: ...fully tapping them out 3 Remove the planet gears 40 2 thrust washers 40 8 and bearings 40 6 from the carrier 4 Inspect the parts for wear or damage and replace if necessary 5 With planet gears out remove the plate 40 5 and retaining ring 40 7 Remove the shaft 40 9 from the carrier 40 1 Inspect the parts for wear or damage and replace if necessary ...

Page 13: ...rust plate 40 5 into the carrier 40 1 along with the gears 40 2 bearings 40 6 and washers 40 8 3 Being careful to line up the thrust washers 40 8 and bearings 40 6 with the planet pins 40 3 press the pin into the carrier 40 1 4 Replace retaining rings 40 4 If the pins are not lined up properly the thrust washer can be shattered during the pressing operation ...

Page 14: ... 41 3 bearings 41 2 and washers 41 4 2 Being careful to line up the thrust washers 41 4 and bearings 41 2 with the planet pins 41 6 press the pin into the carrier 41 1 3 Replace the retaining rings 41 5 If the pins are not lined up properly the thrust washer can be shattered during the pressing operation ...

Page 15: ...washer 43 onto the input gear set 41 Insert the input gear set 41 into the gear housing making sure it is against the output gear set 40 and engaged with the output sun gear 47 Put the outer thrust washer 43 in place and slide the input shaft 39 all the way though the output shaft 40 9 Let the input shaft protrude out on the gear end so that all of the spline is showing Make sure the correct end o...

Page 16: ...e thrust collar against the keys and lock down the three set screws 89 6 Slide the brake housing 20 onto the output shaft 40 9 7 Bolt the brake housing 20 loosely into both frames 64 65 Lower the drum so weight of drum is supported by both the brake and gear housings The air line from the brake band air cylinder can be attached at this time 8 Disengage the sliding clutch 27 so you can turn the dru...

Page 17: ... friction discs are used Dip friction discs in lightweight Non EP oil before installation 7 Install the piston 5 into the brake housing 20 and gently tap it down until it is seated making sure not to damage the o rings 8 10 or back up rings 9 11 8 Install the springs 7 into the spring pockets If working in a horizontal position coat the bottom of each spring with grease to keep it in position 9 In...

Page 18: ...ll the motor with the belly of it down and the case drain port up 2 If removed install the cartridge valve 54 3 Install the counterbalance valve 50 into the counter balance block 32 4 Install the o rings 49 into the manifold block 56 and counterbalance block 32 Install the manifold block 56 and counterbalance block 32 using four capscrews 48 5 Install hoses 42 45 58 79 and 80 6 Fill the brake and ...

Page 19: ...ssures b Load being lifted may be more than the winch s rating Reduce the load or re rig to increase mechanical advantage Oil leaks from the vent located on the top of the gearbox a The motor shaft seal may have failed Replace this seal and reduce backpressure if that caused the shaft seal to fail b Brake piston seals may have failed Service the brake section and replace worn parts Winch runs too ...

Page 20: ...EEDLE BEARING 16 1 44333 BEARING HOUSING 17 2 44323 RETAINING RING 18 1 41759 CLUTCH 19 1 44331 INPUT DRIVER 20 1 43221 BRAKE HOUSING 21 8 24905 CAPSCREW 22 1 44322 RETAINING RING 23 OMIT 24 1 43255 THRUST COLLAR 25 2 44688 OIL SEAL 26 OMIT 27 1 44572 CLUTCH SLIDING 28 1 43231 DRUM CLUTCH 29 2 23754 CAPSCREW 30 1 43413 COUPLER 31 2 43233 BUSHING 32 1 42029 COUNTERBALANCE BLOCK 33 6 42048 CAPSCREW ...

Page 21: ...954 PLATE 42 1 42031 HOSE ASSY 43 2 42934 THRUST WASHER 44 3 32477 CAPSCREW 45 1 42030 HOSE ASSY 46 2 41838 STRAIGHT ADAPTER 47 1 43235 OUTPUT SUN GEAR 48 4 43372 CAPSCREW 49 2 32182 O RING 50 1 41867 COUNTERBALANCE VALVE 51 1 32411 HEX PLUG 52 2 29162 BEARING 53 OMIT 54 1 43367 CARTRIDGE VALVE 55 1 44748 COVER 56 1 43368 MANIFOLD BLOCK 57 3 42089 ADAPTER 58 1 42494 HOSE ASSEMBLY 59 1 42841 O RING...

Page 22: ...FT KIT 85 1 43889 CYLINDER SPACER 86 2 41719 O RING PLUG 87 1 43882 CLUTCH YOKE 88 4 20524 CAPSCREW 89 3 21653 SET SCREW 90 4 29614 CAPSCREW 91 1 43890 AIR CYLINDER COVER 92 1 43828 CLEVIS 93 2 43827 PIN CLEVIS 94 2 43409 KEY 95 OMIT 96 OMIT 97 4 43078 SPACER 98 1 34003 O RING 99 1 939243 CLEVIS PIN 100 3 20514 COTTER PIN 101 1 43877 CLUTCH BRACKET 102 OMIT 103 OMIT 104 2 21128 GREASE ZERK 105 1 4...

Page 23: ...23 VISCOSITY CHART ...

Page 24: ...57 45 106 80 64 1 2 20 85 64 51 120 90 72 9 16 12 109 82 65 153 115 92 9 16 18 122 91 73 172 129 103 5 8 11 150 113 90 212 159 127 5 8 18 170 128 102 240 180 144 3 4 10 266 200 160 376 282 226 3 4 16 297 223 178 420 315 252 7 8 9 430 322 258 606 454 364 7 8 14 474 355 284 668 501 401 1 8 644 483 386 909 682 545 1 14 721 541 433 1019 764 611 1 1 8 7 794 596 475 1288 966 772 1 1 8 12 890 668 534 144...

Page 25: ...25 RUFNEK 45 ISOMETRIC DRAWING DO NOT USE MAGNETS ON OR AROUND WINCH TWG PO Box 1130 Jenks OK 74037 1130 USA Phone 918 298 8300 www dovertwg com ...

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