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SEL-0041-001.DOC 
REV-0 

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.

 

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

 

Summary of Contents for TWG Tulsa RN80 PHLXOA1

Page 1: ...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...

Page 2: ...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 During inhaul the brake is not released sinc...

Page 3: ...ion A broken cable or dropped load can cause serious injury or death 4 Make sure that all equipment including the winch and cable is maintained properly 5 Avoid shock loads This type of load imposes a...

Page 4: ...s 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...

Page 5: ...four cap screws 106 4 Remove the motor from the winch by removing four capscrews 88 5 Remove the counterbalance valve 108 from the counterbalance block 76 and inspect the metering hole to make sure it...

Page 6: ...9 113 and remove it from the brake housing 5 Remove the stator plates 12 and friction discs 13 from the brake housing and check them for excessive wear Replace the parts if necessary Be sure to check...

Page 7: ...63 62 on the bottom of the brake housing 20 Disconnect the airline running from the air cylinder 68 to the brake housing 20 Remove the brake housing by sliding the housing off the output shaft 38 At t...

Page 8: ...e the sun gear 44 the input gear set 42 and inner thrust washer 43 Inspect and replace if necessary 6 Remove the sun gear 45 and secondary gear set 41 Inspect and replace if necessary 7 Remove the gea...

Page 9: ...aining rings 6 from the carrier 1 2 Remove the planet pins from the carrier 1 by carefully tapping them out 3 Remove the planet gears 4 thrust washers 3 and bearings 5 from the carrier 4 Inspect the p...

Page 10: ...ing rings 7 from the carrier 1 2 Remove the planet pins 2 from the carrier 1 by carefully tapping them out 3 Remove the planet gears 6 thrust washers 3 bearings 4 and spacers 5 from the carrier 4 Insp...

Page 11: ...ng rings 7 from the carrier 2 Remove the planet pins 4 from the carrier 1 by carefully tapping them out 3 Remove the planet gears 2 thrust washers 3 bearings 6 and spacers 5 from the carrier 4 Inspect...

Page 12: ...careful to line up the thrust washers 3 and bearings 6 with the planet pins 4 press the pins into the carrier If the pins are not lined up properly the thrust washer can be shattered during the press...

Page 13: ...st washers 3 into the carrier 1 2 Being careful to line up the thrust washers 3 and bearings 4 with the planet pins 2 press the pins into the carrier If the pins are not lined up properly the thrust w...

Page 14: ...rs 3 into the carrier 1 2 Being careful to line up the thrust washers 3 and bearings 5 with the planet pins 2 press the pins into the carrier 1 If the pins are not lined up properly the thrust washer...

Page 15: ...he adapter 58 making sure not to damage the o ring 57 Next install the secondary gear set Note Make sure to line up all three planet gears in secondary gear set with the gear housing and sun gear as i...

Page 16: ...brake band may need to be readjusted once it s in the field 3 Install the inner thrust collar 24 making sure the half moon slots are lined up with the key slots in the output shaft 38 Tap the three ke...

Page 17: ...urn the drum to make sure it is not binding 10 If necessary install the air cylinder 105 and the air cylinder cover 91 to the brake housing with four capscrews 69 and spacers 97 11 Install the bracket...

Page 18: ...iston 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 6 Install the springs 7 into the spring pockets in the pist...

Page 19: ...all the o ring 107 into the manifold block 93 and counterbalance block 76 4 Install the counter balance valve 108 into the counterbalance block 76 5 Install the manifold block 93 and counter balance b...

Page 20: ...should a Relief valve setting may be too low to allow proper lifting Increase relief valve pressure setting Note Do not exceed recommended system pressures b Load being lifted may be more than the wi...

Page 21: ...HOUSING 17 2 44323 RETAINING RING 18 1 41759 CLUTCH 19 1 44337 INPUT DRIVER 20 1 44420 BRAKE HOUSING 21 2 44439 BUSHING 22 1 44417 RING INPUT GEAR 23 1 21042 BEARING 24 1 42938 THRUST COLLAR 25 2 4292...

Page 22: ...9 GEAR HOUSING 61 8 30203 CAPSCREW 62 8 20318 NUT 63 8 20559 LOCKWASHER 64 1 44434 RIGHT HAND FRAME 65 1 44435 LEFT HAND FRAME 66 1 44461 BRAKE BAND 67 1 43882 CLUTCH YOKE 68 1 42929 BRAKE BAND AIR CY...

Page 23: ...4 43078 SPACER 98 1 34003 O RING 99 1 939243 CLEVIS PIN 100 3 20514 COTTER PIN 101 1 43367 12 VOLT CARTRIDGE VALVE 102 1 43879 CLUTCH PLATE 103 OMIT 104 1 42986 CLUTCH OUT LABEL 105 1 44340 AIR CYLIND...

Page 24: ...24 VISCOSITY CHART...

Page 25: ...7 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 2...

Page 26: ...26 RUFNEK 80 ISOMETRIC DRAWING TWG PO Box 1130 Jenks OK 74037 1130 USA Phone 918 298 8300 www dovertwg com...

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