Tulsa Rufnek 100, Rufnek 80 Service Manual

DESIGN SERIES 001

RUFNEK 100

AND

MODEL 80

SERVICE MANUAL

GENERAL INFORMATION ..........................................................................................................................4

INTRODUCTION AND THEORY OF OPERATION ................................................................................................................. 4

ASSEMBLY NUMBER EXPLANATION................................................................................................................................... 4

WINCH BREAK-IN .................................................................................................................................................................. 4

MODEL CODES ...........................................................................................................................................5

MAINTENANCE............................................................................................................................................6

OIL LEVELS............................................................................................................................................................................ 7

BRAKE IDENTIFICATION AND ADJUSTMENT...................................................................................................................... 8

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

DRUM BRAKE DISASSEMBLY............................................................................................................................................. 10

ADJUSTABLE OIL BRAKE DISASSEMBLY.......................................................................................................................... 11

NON-ADJUSTABLE BRAKE DISASSEMBLY ....................................................................................................................... 12

RUFNEK BRAKE DISASSEMBLY......................................................................................................................................... 13

CLUTCH AND DRUM DISASSEMBLY.................................................................................................................................. 14

GEARBOX DISASSEMBLY................................................................................................................................................... 15

GEAR INSPECTION INSTRUCTIONS.................................................................................................................................. 16

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

GEARBOX ASSEMBLY ........................................................................................................................................................ 17

DRUM BRAKE ASSEMBLY .................................................................................................................................................. 18

ADJUSTABLE OIL BRAKE ASSEMBLY................................................................................................................................ 19

NON-ADJUSTABLE OIL BRAKE ASSEMBLY....................................................................................................................... 20

RUFNEK ADJUSTABLE OIL BRAKE ASSEMBLY ................................................................................................................ 21

CLUTCH AND DRUM ASSEMBLY........................................................................................................................................ 22

TROUBLESHOOTING................................................................................................................................23

BILL OF MATERIAL...................................................................................................................................24

ADJUSTABLE BRAKE BILL OF MATERIAL ...........................................................................................27

NON ADJUSTABLE BRAKE BILL OF MATERIAL ..................................................................................27

RUFNEK BRAKE BILL OF MATERIAL.....................................................................................................28

TORQUE SPECIFICATIONS CHART ........................................................................................................ 29

CLUTCH INSPECTION ..............................................................................................................................30

ISOMETRIC VIEW ......................................................................................................................................31

ADJUSTABLE BRAKE, HYDRAULIC MOTOR, & CLUTCH POSITION INDICATOR VIEWS................ 32

SEL-0049-001.DOC REV-0 JAN 2006

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. Additionally, a thorough knowledge of the equipment and its performance capabilities must be understood. These general safety guidelines are offered, however local rules and regulations or national standards may also apply. Recommended references are, but not limited to, ANSI B30, OSHA 1910, AWS D 14.3, and SAE J706.

Additional information can be found at http://www.team-twg.com/TulsaWinch/

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage.

Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property.

Mounting:

Winch mounting must be secure and able to withstand the applied loads.

• The stability of the mounting system must be 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 pressures.

Relief valves should be set to winch manufacturer’s specifications. Insure that all PTO’s and drivelines are sized appropriately for the winch manufactures speed and torque specifications.

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.

Ground personnel should remain a safe distance from the load and winch cable

at least 1 ½ times the length of cable measured from the winch to the load. Must stay clear of the cable at all times. A broken cable can cause serious injury or death. Must avoid shock loads.

Shock loads can impose a strain on the winch that can be many times the design

rating. Must be aware of the fleet angle of the winch.

All loads should only be pulled with the load line perpendicular to the drum shaft,

this is to avoid excessive stresses on the winch and will help prevent the cable

from building on one side of the drum flange. Must wear personnel protective equipment (PPE) if required. Check the local, state and federal regulations 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 over spooling

of the drum and causing bird nesting of the cable on the drum. Inspect the brake

for wear of the lining and the actuation method. Must inspect the load control brake.

These winches can be equipped with two (2) forms of dynamic braking. The

worm brake is one method and is adjustable for pay-out load control. Before a

load is handled the load should be pulled tight and stopped to check this brake.

The second method is a hydraulic lowering control that is not field adjustable.

The same method should be used to check this brake.

Operation:

• All winch controls must be well marked for function to avoid confusion.

• Insure that the PTO is disengaged when the winch is not in use.

• All winch controls must be located to provide the operator with a clear view of the

load.

• The clutch must be inspected daily for proper operation.

• The winch cable should be inspected daily for serviceability.

• A minimum of five wraps of tightly wound cable must remain on the drum.

GENERAL INFORMATION

GENERAL INFORMATIONGENERAL INFORMATION

INTRODUCTION AND THEORY OF OPERATION

INTRODUCTION AND THEORY OF OPERATIONINTRODUCTION AND THEORY OF OPERATION

The Tulsa worm gear winch is operated by turning the input of the worm using a hydraulic motor or PTO driven sprocket and chain. The winch utilizes the adjustable, spring applied, multiple disc oil brake that activates only during pay-out to provide maximum efficiency during pay-in. The torque is transferred from the gearbox through the drum shaft which is keyed to a mechanically actuated sliding clutch that, when engaged, transfers the torque to the drum.

ASSEMBLY NUMBER EXPLANATION

ASSEMBLY NUMBER EXPLANATIONASSEMBLY NUMBER EXPLANATION

This manual is for design series 001. 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.

ASSEMBLY # SERIES

81370 001

DESIGN

WINCH BREAK

WINCH BREAK----IN

WINCH BREAKWINCH BREAK

Winches, like any other kind of machinery, require a “break-in” period to perform well and to maximize their life. The following guidelines should be used in the break-in of Tulsa Winches.

Use extreme care when first spooling cable onto the winch. DO NOT run the winch at high speeds when performing this operation. Make sure that the cable is unrolled in a line (to prevent kinks) and SLOWLY inhaul the winch to install the cable.

DO NOT exceed one half rated load or one half rated line speed for the first thirty minutes of operation. This will insure that the worm and gear have an opportunity to wear in properly. Periodically, check the gearbox for temperature rises and allow the winch to cool down between pulls. Worm gear winches are designed and intended for intermittent duty application only; using them in extremely long pulls may generate excessive heat and shorten the life of the winch.

ININ

RN100 W M R F O M X

Gear Type

W=Worm P=Planetary

Drive Type

H=Hydraulic M=Mechanical

Gearbox Position

L=Left R=Right (viewed from rear of truck)

Input Shaft Location

F=Front R=Rear X=Does not apply (viewed from rear of truck)

Winch Type

M=Mechanical H=Hydraulic

G=Speed Reducer

No. of Worm Starts

S=Single D=Double T=Triple

Worm Angle

L=Left R=Right

Gearbox Location

L=Left R=Right (viewed from rear of truck)

MODEL CODES

MODEL CODESMODEL CODES

M80 S L R F O D CL

THE RUFNEK SERIES

WINCHES ARE ONLY

AVAILABLE WITH LEFT

HAND GEARS.

Motor Type

1. Single Speed Gear Motor

2. Two Speed Gear Motor

3. Single Speed Geroler Motor

4. Two Speed Geroler Motor

5. Piston

6. Vane X. No Motor

Clutch Device

M=Mechanical A=Air

Cable Spooling

O=Over Drum U=Under Drum (viewed from rear of truck)

Motor Type

CL-CharLynn

Motor Mount

D=Direct Mount X=No Motor

Cable Spooling

O=Over Drum U=Under Drum (viewed from rear of truck)

Input Shaft Location

F=Front R=Rear X=Does not apply (viewed from rear of truck)

MAINTENANCE

MAINTENANCEMAINTENANCE

Tulsa Winch worm gear driven winches require regular maintenance to ensure safe and reliable operation. Regular oil changes with the correct oil for the ambient temperature conditions and an annual inspection of the wear components are strongly recommended.

Maintenance Scheduling

The owner is to ensure proper inspection intervals, in compliance with the API RP 2D Section 4, ANSI B30.5, 5-2.3, or ANSI B30.7, 7-2.1, and will review winch usage categories on a periodic basis. A qualified inspector should perform all maintenance and inspections.

USE

(HRS PER

MONTH)

0-10 PRE-USE, ANNUAL

11-50 PRE-USE, QUARTERLY

51+ PRE-USE, MONTHLY

API RP 2D RECOMMENDED

INSPECTION SCHEDULE

Oil Maintenance

The oil in the gear section and the brake section should be changed every 1000 hrs or 6 months of normal usage. If your winch is mounted with a drum brake, do not fill the

brake with oil.

• Tulsa Winch recommends that the oil level in the gearbox be checked and adjusted as part of the pre-use inspection. If the oil level drops frequently or oil leakage is detected during an inspection, maintenance should be performed to correct any problems.

GEARBOX OIL CAPACITY = 8 QTS

• Gearbox oil level inspection is achieved by removing the oil level inspection plug and visually inspecting the oil level. Minimum oil level is to the bottom of the threads of the inspection hole. Refer to the chart below for the recommended oil type and grade for your application.

MOBIL SHC 626

MOBILUBE HD80W140

SAE 140W AGMA 7 EP

All oils must meet MIL-PRF2105E standards. Substitution from a reputable

manufacturer is allowed as long as type and grade are maintained.

GEARBOX OIL LEVEL

OIL LEVELS

OIL LEVELSOIL LEVELS

GEARBOX FILL/VENT

GEARBOX OIL DRAIN

BRAKE

FILL/VENT

BRAKE

OIL DRAIN

BRAKE

OIL LEVEL

BRAKE IDENTIFICATION

AKE IDENTIFICATION AND ADJUSTMENT

BRBR

AKE IDENTIFICATIONAKE IDENTIFICATION

In general, worm brakes on Tulsa winches should be set to hold the load you are currently working with. Excessive brake torque will result in excessive heat generation and brake wear. The best way to insure proper brake adjustment is to pull the cable tight against the load and stop to ensure the brake holds. If it doesn’t, tighten the brake slightly and try it again. If the brake doesn’t respond to adjustment the brake must be serviced.

If the input to the winch is accessible and a torque wrench can be adapted to it, the brake can be set with a torque wrench. The Model 80 brake is shipped from the factory pre-set at 185 Ft.-Lbs.

ADJUSTABLE SHOE BRAKE

To tighten the brake, remove the two capscrews located in the set of holes in the top and bottom of the brake cover. Loosen the two capscrews in the slotted holes and rotate the brake clockwise.

The direction of braking can be changed by replacing the cam with the opposite version. For detailed service instructions, contact your Tulsa Winch distributor or the factory.

ADJUSTABLE MULTIPLE DISC OIL BRAKE

This is the standard version of the multiple disc oil brake. This style of brake can be adjusted by turning the hex adjuster counter-clockwise to increase brake and clockwise to decrease brake. The direction of braking for all multiple disc brakes can be changed by removing the cam clutch, turning it over, and re-installing it. For detailed service instructions, contact your Tulsa Winch distributor or the factory.

If the input to the winch is accessible and a torque wrench can be adapted to it, the brake can be set with a torque wrench. The RN100W brake is shipped from the factory pre-set at 185 Ft.-Lbs.

AND ADJUSTMENT

AND ADJUSTMENT AND ADJUSTMENT

BRAKE IDENTIFICATION AND ADJUSTMENT

BRAKE IDENTIFICATION AND ADJUSTMENT BRAKE IDENTIFICATION AND ADJUSTMENT

CONTINUED

CONTINUEDCONTINUED

Some versions of the Model 80 winch are equipped with a non-adjustable multiple disc oil brake. These winches can be identified by the warning on the cover.

NON-ADJUSTABLE MULTIPLE DISC OIL BRAKE

CAUTION DURING REMOVAL!

SPRING LOADED COVER!

These brakes require no regular adjustment. The direction of braking for all multiple disc brakes can be changed by removing the cam clutch, turning it over, and re-installing it. For detailed service instructions, contact your Tulsa Winch distributor or the factory.

______________________________________________________________________

RUFNEK ADJUSTABLE MULTIPLE DISC OIL BRAKE

This brake is the Rufnek version of the adjustable oil brake. This is the latest design of the worm-driven winch brakes. This style of brake can be adjusted by turning the hex adjuster counter-clockwise to increase brake and clockwise to decrease brake. The direction of braking for all multiple disc brakes can be changed by removing the cam clutch, turning it over, and re-installing it. For detailed service instructions, contact your Tulsa Winch distributor or the factory.

If the input to the winch is accessible and a torque wrench can be adapted to it, the brake can be set with a torque wrench. The RN100W brake is shipped from the factory pre-set at 185 Ft.-Lbs.

DISASSEMBLY

DISASSEMBLYDISASSEMBLY

DRUM

DRUM BRAKE DISASSEMBLY

DRUM DRUM

1. Loosen the capscrews (31).

2. Remove the capscrews (88) from the cover (86).

3. Remove the cover (86) from the gearbox.

4. Remove the brake shoes (98).

5. Remove the nut (97) and washer (96).

6. Use the two threaded holes in the brake drum (95) and a gear puller to remove the brake drum.

BRAKE DISASSEMBLY

BRAKE DISASSEMBLYBRAKE DISASSEMBLY

7. Inspect parts as follows, replace if necessary:

A. Inspect the brake shoes (98) for

wear. If the shoe linings are worn flush with the rivet heads, the shoes must be replaced.

B. Inspect the brake drum (95) for

severe wear or scoring.

C. Check the inside lower part of the

gearbox housing for the presence of oil. Replace the seal (37) if oil is present

If replacing the seal (37), first drain the oil from the gearbox then remove the capscrews (94) and brake cover (93).

+ 22 hidden pages

Tulsa Rufnek 100, Rufnek 80 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual