Dover RUFNEK 100, Service Manual

Page 1: ...LY 11 E INPUT PLANET SET DISASSEMBLY 12 F SECONDARY PLANET SET DISASSEMBLY 13 G OUTPUT PLANET SET DISASSEMBLY 14 GENERAL ASSEMBLY 15 H OUTPUT PLANET SET ASSEMBLY 15 I SECONDARY PLANET SET ASSEMBLY 16...

Page 2: ...the 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 004 In the case of a majo...

Page 3: ...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 fla...

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...

Page 5: ...unted 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 d...

Page 6: ...e manifold block 78 from the motor by removing the four capscrews 25 4 Remove the motor 63 from the winch by removing four capscrews 30 5 Remove the counterbalance valve 28 from the counterbalance blo...

Page 7: ...up as the cap screws are loosened Carefully remove the cover 18 from the brake housing 16 Inspect the o ring 61 for damage 2 Remove the springs 59 from the piston 54 and check the free height Each spr...

Page 8: ...r plate for scoring caused by the removal of the piston and polish if necessary Friction discs should measure no less than 055 in thick and stator plates should measure no less than 068 in thick 6 To...

Page 9: ...ashers 71 72 on the bottom of the brake housing 16 Disconnect the airline running from the air cylinder 15 to the brake housing 16 Remove the brake housing by sliding it off of the output shaft 20 At...

Page 10: ...10 CLUTCH INSPECTION...

Page 11: ...over 3 by removing the six capscrews 30 4 Inspect the o rings 33 104 for wear and replace if necessary 5 Remove the input gear set 22 and thrust washers 34 37 Inspect and replace if necessary 6 Remove...

Page 12: ...ove the retaining rings 22 4 from the planet pins 22 5 2 Remove the pins 22 5 from the carrier 22 1 by carefully tapping them out 3 Remove the planet gears 22 2 thrust washers 22 6 and bearings 22 3 f...

Page 13: ...Remove the retaining rings 23 4 from the planet pins 23 5 2 Remove the pins 23 5 from the carrier 23 1 by carefully tapping them out 3 Remove the planet gears 23 2 thrust washers 23 6 and bearings 23...

Page 14: ...rom the planet pins 24 5 2 Remove the pins 24 5 from the carrier 24 1 by carefully tapping them out 3 Remove the planet gears 24 2 thrust washers 24 6 and bearings 24 3 from the carrier 4 Remove the t...

Page 15: ...24 7 into the carrier 24 1 along with the gears 24 2 bearings 24 3 and thrust washers 24 6 2 Being careful to line up the thrust washers 24 6 and bearings 24 3 with the planet pins 24 5 press the pin...

Page 16: ...1 along with the gears 23 2 bearings 23 3 and thrust washers 23 6 2 Being careful to line up the thrust washers 23 6 and bearings 23 3 with the planet pins 23 5 press the pins into the carrier 3 Repla...

Page 17: ...ong with the gears 22 2 bearings 22 3 and thrust washers 22 6 2 Being careful to line up the thrust washers 22 6 and bearings 22 3 with the planet pins 22 5 press the pins into the carrier 3 Replace t...

Page 18: ...put sun gear 8 then install the thrust washer 37 onto the secondary gear set 23 Next install the secondary gear set 23 into the gear housing 10 Make sure to line up all three planet gears in the secon...

Page 19: ...ake band air cylinder 76 making sure the rod of the air cylinder is going through the bracket on the brake band 77 Secure it to the bracket 90 with the clevis pin 107 and cotter key 108 Tighten the ad...

Page 20: ...his time 8 Disengage the sliding clutch 13 so you can turn the drum freely and tighten all bolts through the frames to the proper torque specification see page 28 of this manual 9 Turn the drum to mak...

Page 21: ...y 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 f...

Page 22: ...drain port up 2 If removed install the cartridge valve 75 3 Install the counter balance valve 28 into the counterbalance block 79 4 Install the o ring 26 into the manifold block 78 and counterbalance...

Page 23: ...pressures 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 vent located on the top of the gearbox a The motor shaft sea...

Page 24: ...19 BRAKE COVER 19 2 42868 BUSHING 20 1 42869 OUTPUT SHAFT 21 1 4480 INTELLIGUARD SYSTEM 22 1 4250 INPUT GEAR SET 22 1 1 43183 INPUT CARRIER 22 2 3 42877 PLANET GEAR 22 3 3 30484 NEEDLE BEARING 22 4 3...

Page 25: ...UG 40 2 42930 BUSHING 41 2 44690 OIL SEAL 42 OMIT 43 1 42937 U BOLT 44 2 21214 NUT 45 6 21644 CAPSCREW 46 1 42938 THRUST COLLAR 47 3 42939 KEY 48 1 43696 THRUST COLLAR 49 OMIT 50 1 42932 BALL BEARING...

Page 26: ...0280 FITTING 84 1 32145 CAPLUG 85 2 20521 NUT 86 2 20518 LOCKWASHER 87 1 42495 HOSE ASSEMBLY 88 1 43459 HOSE ASSEMBLY 89 3 21653 SET SCREW 90 1 42955 MOUNTING BRACKET 91 2 29472 CAPSCREW 92 2 21128 GR...

Page 27: ...27 VISCOSITY CHART...

Page 28: ...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 29: ...43 44 21 20 45 77 73 71 72 74 70 19 41 40 39 93 10 14 23 6 23 3 23 2 23 6 23 5 23 4 23 7 23 1 63 79 25 2 4 81 1 87 83 82 80 30 82 2 88 78 80 26 29 28 75 26 22 2 22 3 22 6 22 5 22 4 22 7 22 1 22 6 24...