Tulsa RUFNEK 30, Service Manual

Page 1: ...Y 9 RUFNEK 30 BRAKE DISASSEMBLY 9 MODEL 34 BRAKE DISASSEMBLY 10 CLUTCH AND DRUM DISASSEMBLY 11 GEARBOX DISASSEMBLY 12 GEAR INSPECTION INSTRUCTIONS 13 ASSEMBLY 14 GEARBOX ASSEMBLY 14 MODEL 34 BRAKE ASSEMBLY 15 RUFNEK 30 BRAKE ASSEMBLY 15 CLUTCH AND DRUM ASSEMBLY 16 TROUBLESHOOTING 17 BILL OF MATERIAL 18 TORQUE SPECIFICATIONS CHART 19 CLUTCH INSPECTION 19 ISOMETRIC VIEW 19 RUFNEK BRAKE HYDRAULIC MOT...

Page 2: ...ved 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...

Page 3: ...tch 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 nesti...

Page 4: ...eries designation number will be issued for the winch A new manual will also be created for that specific design series WINCH BREAK WINCH BREAK WINCH BREAK WINCH BREAK IN IN IN IN Winches like any other kind of machinery require a break in 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 o...

Page 5: ...o Speed Gear Motor 3 Single Speed Geroler Motor 4 Two Speed Geroler Motor 5 Piston 6 Vane X No Motor RN30 W M R F O M X Winch Type M Mechanical H Hydraulic No of Worm Starts S Single D Double Worm Angle L Left R Right Input Shaft Location F Front R Rear X Does not apply viewed from rear of truck Cable Spooling O Over Drum U Under Drum viewed from rear of truck Motor Mount D Direct Mount X No Motor...

Page 6: ...f normal usage 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 3 QTS Gearbox oil level inspection is achieved by removing the oil level inspection plug and visually inspectin...

Page 7: ...7 OIL LEVELS OIL LEVELS OIL LEVELS OIL LEVELS BRAKE OIL DRAIN BRAKE OIL LEVEL BRAKE FILL VENT GEARBOX OIL LEVEL GEARBOX FILL VENT GEARBOX OIL DRAIN ...

Page 8: ...hten the brake loosen the two capscrews in the slotted holes and rotate the brake in the direction shown If the brake needs to be reversed remove those same two capscrews rotate the cam 60 degrees and reinstall the capscrews in the other set of holes which have just been revealed After adjustment be sure to re tighten the cam capscrews securely ADJUSTABLE MULTIPLE DISC OIL BRAKE RN30W This style o...

Page 9: ... the capscrews 94 from the brake cover 96 4 Remove the spring 105 Remove the brake driver 101 along with the brake components 93 103 104 106 and 107 5 Inspect parts as follows replace if necessary A Inspect the friction discs 104 for uneven or excessive wear Friction discs should measure no less than 055 in thick B Inspect the stator plates 103 for warpage or excessive damage C Inspect the spring ...

Page 10: ...holes in the brake drum 83 and a gear puller to remove the brake drum 7 Inspect parts as follows replace if necessary A Inspect the brake shoes 86 for wear If the shoe linings are worn flush with the rivet heads they must be replaced B Inspect the brake drum 83 for severe wear or scoring C Check the inside lower part of the brake housing 31 for the presence of oil Replace the seal 55 if oil is pre...

Page 11: ...y 109 and sliding clutch 55 7 Remove the keys 67 and collar 10 from the shaft 68 by loosening set screw 9 8 Remove the brake band assembly 8 by loosening the nuts on the rod 21 to remove tension on the spring 22 Then remove the cotter key 32 pin 33 attaching clevis 28 to control arm 27 Finally remove the capscrews 16 washers 23 and nuts 24 attaching the brake band to the frame 9 Slide the drum 14 ...

Page 12: ...ft 68 Finally remove the spacer 73 carrier 72 and keys 70 4 Remove the worm 57 from the housing 61 by removing either the motor 116 and motor adapter 112 or just the end cap 51 depending on the type of drive 5 From the brake end push the worm 57 out of the housing 61 If the brake has not been removed see brake disassembly on page 9 or 10 6 Inspect parts as follows replace if necessary A Inspect th...

Page 13: ...STRUCTIONS GEAR INSPECTION INSTRUCTIONS Check gear wear by removing the cover and visually inspecting the bronze gear If the gear is worn such that there is no visible land on the throat of the gear between the gear flanks as shown in picture above the gear should be replaced LAND ...

Page 14: ...d cap 51 Attach the end cap 51 to the housing 61 with six capscrews 56 using gasket 52 3 Install the keys 58 into the output shaft 68 4 Slide the carrier 72 over the keys 70 Install the spacer 73 using the two pins 74 Slide the gear 75 and the other carrier 72 onto the shaft and secure with eighteen capscrews 71 nuts 81 and washers 80 5 Install the assembled gear onto the shaft 68 Slide the bushin...

Page 15: ... manual RUFNEK RUFNEK RUFNEK RUFNEK 30 30 30 30 BRAKE ASSEMBLY BRAKE ASSEMBLY BRAKE ASSEMBLY BRAKE ASSEMBLY 1 Press the oil seal 90 into the brake housing 91 Attach the brake housing to the gearbox with eight capscrews 89 using gasket 110 2 Install the key 92 and coupler 108 onto the worm Next install the clutch driver assembly Items 93 101 106 and 107 onto the coupler 108 3 With the retaining rin...

Page 16: ...he yoke MUST be centered in the groove with the clutch fully engaged in order for the clutch position indicator to be properly adjusted See FIG 1 The switch is a normally open electrical switch that is actuated by disengaging the clutch which closes the circuit With the clutch fully engaged adjust the switch in until the warning device is activated then back out 1 4 turn to deactivate the warning ...

Page 17: ...he parts as required Winch runs too slow a Low flow rate Check the flow rate and increase if necessary b Hydraulic motor worn out Replace the motor Cable drum won t free spool a Winch not mounted squarely Check mounting and confirm that the winch is mounted on a level surface b Clutch not disengaged Disengage the clutch Hydraulic fluid leaks from the vent in the gearbox a Damaged motor shaft seal ...

Page 18: ...NG CLUTCH 12 1 23598 DRUM CLUTCH 13 6 20407 CAPSCREW 14 1 23595 DRUM 15 1 21154 U BOLT 16 5 20270 CAPSCREW 17 OMIT 18 OMIT 19 8 20518 LOCKWASHER 20 9 20267 NUT 21 5 20521 NUT 22 1 20958 SPRING 23 16 20526 LOCKWASHER 24 15 20271 NUT 25 1 20112 ROD 26 2 20522 CAPSCREW 27 1 20094 ARM 28 1 20054 CLEVIS 29 4 20617 WASHER 30 4 28578 CAPSCREW 31 1 21365 HOUSING 32 1 20514 COTTER PIN 33 1 939243 CLEVIS PI...

Page 19: ... 20281 OIL SEAL 56 16 30205 CAPSCREW 57a 1 21641 RIGHT HAND WORM M34 57b 1 21640 LEFT HAND WORM M34 57c 1 44068 MECHANICAL WORM RN30 57d 1 44070 HYDRAULIC WORM RN30 58 1 25393 KEY 59 8 939262 CAPSCREW 60 2 32840 BUSHING 61 1 21556 HOUSING 62 8 20520 LOCKWASHER 63 8 20274 NUT 64 3 20286 PIPE PLUG 65 1 939269 LEFT FRAME 66 1 20293 RIGHT FRAME 67 2 20098 KEY 68 1 22443 SHAFT 69 2 32839 BUSHING 70 2 2...

Page 20: ... 43964 BRAKE HOUSING 92 1 25519 KEY 93 1 44151 O RING 94 8 20522 CAPSCREW 95 1 13050 BREATHER 96 1 43966 BRAKE COVER 97 1 41406 ADJUSTING NUT 98 1 43960 SPRING PLATE 99 1 41411 O RING 100 2 21684 PLUG 101 1 44150 BRAKE DRIVER 102 1 44145 RETAINING RING 103 6 33564 FRICTION DISC 104 11 44141 STATOR PLATE 105 1 33559 SPRING 106 1 29084 RETAINING RING 107 1 33565 CAM CLUTCH 108 1 44142 COUPLER 109 1 ...

Page 21: ...0 53 42 7 16 20 55 41 33 78 58 47 1 2 13 76 57 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 16 297 223 178 420 315 252 7 8 9 430 322 258 606 454 364 7 8 14 474 355 284 668 501 401 1 8 644 483 386 909 682 545 1 14 721 541 433 1019 764 611 1 1 8 7 794 5...

Page 22: ...22 CLUTCH INSPECTION CLUTCH INSPECTION CLUTCH INSPECTION CLUTCH INSPECTION ...

Page 23: ...23 ISOMETRIC ISOMETRIC ISOMETRIC ISOMETRIC VIEW VIEW VIEW VIEW FOR RUFNEK BRAKE AND HYDRAULIC MOTOR SEE PAGE 24 ...

Page 24: ... CLUTCH POSITION INDICATOR RUFNEK BRAKE HYDRAULIC MOTOR CLUTCH POSITION INDICATOR RUFNEK BRAKE HYDRAULIC MOTOR CLUTCH POSITION INDICATOR RUFNEK BRAKE HYDRAULIC MOTOR CLUTCH POSITION INDICATOR RUFNEK OIL BRAKE TWG PO Box 1130 Jenks OK 74037 1130 USA Phone 918 298 8300 www dovertwg com ...