Dover TWG RUFNEK 50P, Service & Repair Manual

Page 1: ...SECTION DISASSEMBLY 12 INPUT PLANET SET DISASSEMBLY 13 SECONDARY PLANET SET DISASSEMBLY ERROR BOOKMARK NOT DEFINED OUTPUT PLANET SET DISASSEMBLY 14 ASSEMBLY 15 OUTPUT PLANET SET ASSEMBLY 15 SECONDARY...

Page 2: ...d 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 n...

Page 3: ...heck 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...

Page 4: ...40 PSI the brake valve will open and dynamically control the lowering of the load ASSEMBLY NUMBER EXPLANATION This manual is for design series 001 In the case of a major design change implementation a...

Page 5: ...determine the need for oil changes but it should be checked at a minimum of every 500 hours Factors such as extremely dirty conditions or widely varying temperature changes may dictate even more frequ...

Page 6: ...OIL CAPACITY GEARBOX 7 QTS BRAKE 25 QTS Do not use EP type gear lubes in the brake section of this winch EP lubes may prevent the clutch from locking up which in turn causes the load to fall resulting...

Page 7: ...d at the top of the gear housing 3 and the top of the brake cover 2 Inspect the oil for signs of metallic particles and or burning and dispose of in a proper manner Then re install the drain plugs Fil...

Page 8: ...cap screws 88 4 Remove the motor 1 from 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 n...

Page 9: ...18 19 52 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 and replace if necessary Be sure to check the...

Page 10: ...68 yet Disconnect the airline from the backside of the brake housing 20 that goes to the brake band air cylinder You can now remove the brake band assembly 66 Note which frame the mounting bolts are o...

Page 11: ...r BAD The reverse draft ensures the clutch stays engaged during pay in Without the correct draft the clutch could dis engage unpredictably CLUTCH REPLACEMENT CRITERIA If 1 4 of the surface of the face...

Page 12: ...d system is not serviceable in the field Return to an authorized dealer for service 3 Remove the eight capscrews 21 from the end cover 55 and remove the end cover 4 Inspect the o rings 36 59 and repla...

Page 13: ...41 6 2 Remove the pins from the carrier 41 1 by carefully tapping them out 3 Remove the planet gears 41 3 thrust washers 41 4 and bearings 41 2 from the carrier 42 1 4 With the planet gears 41 3 out...

Page 14: ...lly tapping them out 3 Remove the planet gears 40 2 thrust washers 40 8 and bearings 40 6 from the carrier 40 1 4 Inspect the parts for wear or damage and replace if necessary 5 With the planet gears...

Page 15: ...plate 40 5 into the carrier along with the gears 40 2 bearings 40 6 and washers 40 8 3 Be careful to line up the thrust washers 40 8 and bearings 40 6 with the planet pins 40 3 press the pin into the...

Page 16: ...3 bearings 41 2 and thrust 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 pins into the carrier 42 1 If the pins are not lined up...

Page 17: ...ear set 40 4 Install the thrust washer 43 onto the input gear set 41 Insert the input gear set 41 into the gear housing 60 making sure it is against the output gear set 40 and engaged with the output...

Page 18: ...into their slots in the output shaft 5 If necessary install the new drum clutch 28 using six capscrews 33 Torque to specified torque see page 25 of this manual Then align the coupler 30 with the keys...

Page 19: ...92 Install the cotter pins 100 into the clevis pins 93 in order to secure their positions 15 Connect shop air to the cylinder and apply air in both directions With the clutch fully engaged air applie...

Page 20: ...embly onto the input shaft 39 2 6 Install the stator plates 12 and friction discs 13 starting with a stator plate and alternating between friction discs and stator plates until seven stator plates and...

Page 21: ...portable hydraulic pump Full release should be obtained at 400psi plus or minus 20psi Also check the brake for proper operation by applying 0psi to the brake port and adapting a torque wrench to the...

Page 22: ...ll the counter balance valve 50 into the counterbalance block 32 4 Install the o rings 49 into the manifold block 56 and counterbalance block 32 Install the manifold block 56 and counter balance block...

Page 23: ...the appropriate pressure for the application 2 The load being lifted may be more than the winches rating Verify weight and reduce the load or re rig it to increase mechanical advantage Oil leaks from...

Page 24: ...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 25: ...G RETAINING 2 18 CLUTCH SPRAG 1 19 BRAKE DRIVER BLANK 1 20 HOUSING BRAKE 1 21 CAPSCREW 8 22 RING RETAINING 1 24 THRUST COLLAR 1 25 SEAL OIL 2 27 CLUTCH SLIDING 1 28 CLUTCH DRUM 1 29 CAPSCREW 2 30 COUP...

Page 26: ...BAND 1 69 CAPSCREW 4 70 CAPSCREW 2 71 NUT 4 72 LOCKWASHER 2 73 MOUNTING BRACKET AIR CYLINDER 1 74 PLUG ADAPTER 1 75 BREATHER 1 76 TEE SWIVEL 1 77 ADAPTER STRAIGHT 1 78 FITTING TEE BRANCH 2 79 HOSE 1 8...

Page 27: ...GREASE ZERK 45 DEG 2 105 COLLAR THRUST 1 106 CAPSCREW 2 107 PLATE LOGO INTELLIGUARD 1 108 U BOLT 1 109 TAG RUFNEK 1 111 RACE THRUST 3 112 WASHER HARDENED STEEL 2 113 CUP EXP PLG 2 114 HOLLOW LOCK SOC...

Page 28: ...28 CROSS SECTIONAL ASSEMBLY DRAWING...

Page 29: ...29 EXPLODED ASSEMBLY DRAWING...

Page 30: ...30 INSTALLATION DRAWING...