Dover RUFNEK 100, Service Manual

21 

62

60

59

56

2

94

81

54

61

57

69

58

67

55

64

95

66

66

65

BRAKE

PORT

67

53

52

50

68

16

If a complete tear down is not 
necessary, make sure the 
input shaft (21) does not 
move during removal of the 
drum.  If the shaft is allowed 
to move,

the input spacer 

(104) will fall into the gear set 
ultimately causing failure to 
the gear section of the winch. 
The gear cover (3) will have to 
be removed to re-position the 
spacer on the input shaft. 

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 
free turning in the pay in direction. 

 
2.  Measure the distance from the face of the 

brake housing to the end of the shaft as 
shown above. 

 
3.  If needed, add shims (113, 114) inside input 

driver (64) on motor side to achieve 
dimension shown above. 

  
4.  Install the bearing housing assembly that 

contains parts 50 and 68 into the brake 
housing. 

5.  Install the driver/clutch assembly onto the 

input shaft (21). 

 
6.  Install the stator plates (52) and friction 

discs (53) starting with a stator plate and 
alternating between friction discs and stator 
plates until seven stator plates and six 
friction discs are used.   

Dip friction discs in lightweight 

Non-EP oil before installation. 

 
7.  Install the piston (54) into the brake housing 

(16) and gently tap it down until it is seated 
making sure not to damage the o-rings (55, 
57) or back-up rings (56, 58). 

 
8.  Install the springs (59) into the spring 

pockets.  If working in a horizontal position, 
coat the bottom of each spring with chassis 
lube to keep it in position. 

 
9.  Install the cover (16) onto the brake housing 

(16) using four cap screws (60).  Draw the 
cover down evenly, alternating between 
opposite hex bolts.  Make sure that the 
cover is aligned properly with the brake 
housing to orient the motor correctly. 

 
10. Check the brake release with a portable 

hydraulic pump.  Full release should be 
obtained at 340psi, plus or minus 20psi.  
Also, check the brake for proper operation 
by applying 107psi to the brake port and 
adapting a torque wrench to the input shaft.  
The torque in the payout should be 142 to 
162 ft-lbs.