Tulsa Rufnek Intelliguard 80 User manual

SEL-0041-006.DOC
REV-0
RUFNEK 80
SERVICE MANUAL
INTRODUCTION AND THEORY OF OPERATION.....................................................................................2
ASSEMBLY NUMBER EXPLANATION ......................................................................................................2
WINCH MODEL CODES..............................................................................................................................2
MAINTENANCE............................................................................................................................................5
GENERAL DISASSEMBLY..........................................................................................................................6
A. MOTOR DISASSEMBLY................................................................................................................................................................6
B. BRAKE SECTION DISASSEMBLY................................................................................................................................................7
C. DRUM SECTION DISASSEMBLY .................................................................................................................................................8
D. GEAR SECTION DISASSEMBLY................................................................................................................................................10
E. INPUT PLANET SET DISASSEMBLY..........................................................................................................................................11
F. SECONDARY PLANET SET DISASSEMBLY..............................................................................................................................12
G. OUTPUT PLANET SET DISASSEMBLY .....................................................................................................................................13
GENERAL ASSEMBLY..............................................................................................................................14
H. OUTPUT PLANET SET ASSEMBLY ...........................................................................................................................................14
I. SECONDARY PLANET SET ASSEMBLY.....................................................................................................................................15
J. INPUT PLANET SET ASSEMBLY ................................................................................................................................................16
K. GEAR END ASSEMBLY ..............................................................................................................................................................17
L. DRUM SECTION ASSEMBLY......................................................................................................................................................18
M. BRAKE SECTION ASSEMBLY ...................................................................................................................................................20
N. MOTOR ASSEMBLY ...................................................................................................................................................................21
TROUBLESHOOTING................................................................................................................................22
RUFNEK 80 BILL OF MATERIAL .............................................................................................................23
VISCOSITY CHART ...................................................................................................................................26
TORQUE SPECIFICATIONS CHART........................................................................................................27
RUFNEK 80 ISOMETRIC DRAWING ........................................................................................................28
DESIGN SERIES 006

2
INTRODUCTION AND THEORY OF OPERATION
The Rufnek series planetary winch is designed to use a high-speed gear motor,
driving through a multiple disc brake, through three planet sets to the cable drum.
The multiple-disc brake is spring applied and hydraulically released through a port in the
brake housing. During inhaul, the brake is not released since the load is driven through
the one-way cam clutch, bypassing the brake. When the load comes to a stop, the cam
clutch locks up and the load is prevented from moving by the brake.
The brake and brake valve receives its signal any time the winch is in pay out. With
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 006. 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.
DESIGN
ASSEMBLY # SERIES
82021 006
WINCH MODEL CODES
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)
Cable Spooling
O=Over Drum
U=Under Drum
(viewed from rear of truck)
Clutch Device
M=Mechanical
A=Air
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
RN80 P HLXOA1

3
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 and with 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/
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.
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.
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.

4
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 are equipped with two (2) forms of dynamic braking. The spring-
applied/hydraulically-released multi-disc oil brake is one method. 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. The same method should be used
to check this brake.
Operation:
•All winch controls must be well marked for function to avoid confusion.
•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.

5
MAINTENANCE
Tulsa Rufnek series planetary winches, like any other piece of machinery, need to be
periodically serviced and well maintained to insure proper operation.
Good maintenance consists of four steps.
1. A daily inspection to insure that there are no oil leaks present and that all mounting
bolts and other fasteners are tight, and that the wire rope is in good condition.
2. Changing the oil in both the gearbox and the brake section. (Severity of use will
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 frequent servicing).
3. Lubing drum bushings and sliding clutch with grease thru grease fittings located on
drum barrel and clutch.
4. Complete teardowns and component inspections. (Again, severity and frequency of
use will determine how often this should be done). If the equipment that this winch
is mounted 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 determine the source of wear.
Rufnek series planetary winches are designed with a common oil reservoir for the
gearbox and brake. The winches are shipped from the factory filled with Mobilube SHC
SAE 75W-90 synthetic gear oil which is satisfactory for operation in ambient
temperatures from -40°F to +110°F. If winch will be operated in temperatures outside
this range, contact Tulsa Winch for recommendations.
The oil is drained by removing the drain plugs (85 & 81) located at bottom of adapter
cover (58) and bottom of brake cover (2). Then remove the fill plugs (74 & 81) located
at the top of the gear housing (60) 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.
Fill the brake end with Mobilube SHC SAE 75W-90 (1/2 quart), then fill the gear end
with Mobilube SHC SAE 75W-90 oil (9 quarts) and replace both of the fill plugs.
OIL CAPACITY = 9.0 QUARTS

6
GENERAL DISASSEMBLY
A. MOTOR DISASSEMBLY
1. Drain the oil from the brake assembly by
removing the plug (81) from the bottom of
the brake cover (2).
2. Remove hoses (4, 54, 56, 77, & 80).
3. Remove the counterbalance block (76) and
the manifold block (93), from the motor by
removing the four cap screws (106).
4. Remove the motor from the winch by
removing four capscrews (88).
5. Remove the counterbalance valve (108)
from the counterbalance block (76) and
inspect the metering hole to make sure it is
not obstructed. Also, inspect the o-rings on
valve to insure that they are not flat or cut.
Replace if necessary.
6. Motors and counterbalance valves are not
serviceable in the field. Return them to an
authorized dealer for service.
7. Inspect o-rings (98) & (107) for damage.

7
B. BRAKE SECTION DISASSEMBLY
1. Evenly remove the four cap screws (3) that
hold the brake cover (2) in place. Spring
pressure will raise the cover up as the cap
screws are loosened. Carefully remove the
cover (2) from the brake housing (20).
Inspect the o-ring (6) on cover for damage.
2. Remove the springs (7) from the piston (5)
and check the free height. Each spring
should measure at least 1.240 inches with
no force on them.
3. Remove the piston (5) by installing two
pieces of 3/8”-16NC all thread into the two
holes in the top of the piston and run in
evenly until the piston is clear of the
housing. An alternate way of removing the
piston is to use shop air to slowly pressurize
the brake cavity to remove the piston from
the brake housing (20).
4. Inspect the o-rings (8, 10) and back up rings
(9, 11) on the piston, replace if necessary.
Grasp the brake driver/clutch assembly
(assembled items 14, 15, 17, 18, 19, 113)
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. Replace the parts
if necessary. Be sure to check the top stator
plate for scoring caused by the removal of
the piston and polish if needed. Friction
discs should measure no less than .055-in.
thickness and stator plates should measure
no less than .068-in thickness.
6. To disassemble the brake driver/clutch
assembly, remove the retaining ring (17)
from either end of the driver. Then, remove
the brake driver (14) and bearing (15) from
the input driver (19). Next, remove the
sprag clutch (18). Finally, remove the
retaining ring (17) from the other end of the
driver, then remove the second bearing (52)
from the input driver.
Notice the direction of lock-up
on the clutch for re-assembly.
Inspect the input driver and brake driver for
wear, replace if necessary.
7. Remove the bearing housing (16) and
inspect the bearing (52).
8. If the bushing or seal in the brake housing
needs to be replaced, follow the drum
section disassembly and reassembly
sections of this manual prior to reassembly
of the brake..

8
C. DRUM SECTION DISASSEMBLY
1. With the motor and brake disassembled, first
remove the cotter keys (100) and clevis pins
(49) connecting the yoke (67) to the bracket
(90) & air cylinder (105). Second, remove
the eight cap screws (29 & 69), four spacers
(97), air cylinder cover (91), air cylinder
(105), and bracket (90).
You may need to remove the
air lines, so it’s a good idea to
mark them for re-assembly.
2. Support the weight of the drum with a hoist.
Remove the four cap screws (61) along with
the nuts and washers (63, 62) on the bottom
of the brake housing (20). Disconnect the
airline running from the air cylinder (68) to
the brake housing (20). Remove the brake
housing by sliding the housing off the output
shaft (38).
Remove the brake band assembly (66) by
removing two cap screws (70), nuts and
washers (71, 72) from the frames (64 or 65).
Note which frame the mounting bolts are on
for re-assembly. Inspect and replace if
needed.
3. Remove the outer thrust collar (53) by
loosening the three set screws (50).
4. Remove the yoke (67), sliding clutch (27),
and coupler (30). Remove the three keys
(94) and the inner thrust collar (24).
Remove the drum using a hoist. Inspect the
bushings (31) in both ends of the drum.
You should also inspect the bushing
and seal (21, 25) that are located
in the end of the brake housing.

9
CLUTCH INSPECTION

10
D. GEAR SECTION DISASSEMBLY
1. Drain the oil by removing the plug (85)
located on the bottom of the adapter cover
(58).
2. To disassemble the gear section, remove
the Intelliguard™ spacer (39) from the outer
cover (55) by removing three capscrews
(44). Inspect the gear teeth on the
Intelliguard™ (39) for wear. The
Intelliguard™ system is not serviceable in
the field. Return to an authorized dealer for
service.
3. Remove the outer cover (55) by removing
the ten capscrews (112).
4. Inspect the o-rings (57 & 114) for wear and
replace if necessary
5. Remove the input gear set (42) along with
the inner and outer thrust washers (43)
Inspect and replace if necessary.
6. Remove the sun gear (45) and secondary
gear set (41). Inspect and replace if
necessary.
7. Remove the primary housing (58) by
removing eight capscrews (32). Inspect the
o-ring (59) and replace if necessary.
8. Remove the spacer (28) and sun gear (46).
Inspect for wear and replace if necessary.
9. Remove the snap ring (47) from the output
shaft (38).
10. Remove the output gear set (40) and thrust
washer (37). Inspect and replace if
necessary.

11
E. INPUT PLANET SET DISASSEMBLY
1. Remove the retaining rings (6) from the
carrier (1).
2. Remove the planet pins from the carrier (1)
by carefully tapping them out.
3. Remove the planet gears (4), thrust washers
(3), and bearings (5) from the carrier.
4. Inspect the parts for wear or damage and
replace if necessary.

12
F. SECONDARY PLANET SET DISASSEMBLY
1. Remove the retaining rings (7) from the
carrier (1).
2. Remove the planet pins (2) from the carrier
(1) by carefully tapping them out.
3. Remove the planet gears (6), thrust washers
(3), bearings (4), and spacers (5) from the
carrier.
4. Inspect the parts for wear or damage and
replace if necessary.

13
G. OUTPUT PLANET SET DISASSEMBLY
1. Remove the retaining rings (7) from the
carrier.
2. Remove the planet pins (4) from the carrier
(1) by carefully tapping them out.
3. Remove the planet gears (2), thrust washers
(3), bearings (6), and spacers (5) from the
carrier.
4. Inspect the parts for wear or damage and
replace if necessary.

14
1. Insert the gears (2), bearings (6), spacers
(5) and thrust washers (3) into the carrier
(1).
2. Being careful to line up the thrust washers
(3) and bearings (6) with the planet pins (4),
press the pins into the carrier.
3. Replace the retaining rings (7).
GENERAL ASSEMBLY
H. OUTPUT PLANET SET ASSEMBLY
If the pins are not lined up
properly, the thrust washer
can be shattered during the
pressing operation.

15
I. SECONDARY PLANET SET ASSEMBLY
1. Insert the gears (6), bearings (4), spacers
(5), and thrust washers (3) into the carrier
(1).
2. Being careful to line up the thrust washers
(3) and bearings (4) with the planet pins (2),
press the pins into the carrier.
3. Replace the retaining rings (7).
If the pins are not lined up
properly, the thrust washer
can be shattered during
the pressing operation.

16
J. INPUT PLANET SET ASSEMBLY
1. Insert the gears (4), bearings (5) and thrust
washers (3) into the carrier (1).
2. Being careful to line up the thrust washers
(3) and bearings (5) with the planet pins (2),
press the pins into the carrier (1).
3. Replace the retaining rings (6).
If the pins are not lined up
properly, the thrust washer
can be shattered during
the pressing operation.

17
K. GEAR END ASSEMBLY
1. Bolt the gear-housing (60) loosely into both
frames (64, 65).
2. When reassembling, apply grease to parts
such as thrust washers, o-rings, and seals.
Install the output shaft (38) into the gear
housing (60). Slide the thrust washer (37)
onto the output shaft (38). Next, install the
output gear set (40). Then install the
retaining ring (47) onto the output shaft (38).
Push the gear set and shaft back into the
housing until it stops against the thrust
washer (37).
Make sure to line up all
three planet gears in the
output gear set with the
gear housing as it starts
into the housing.
3. Install the sun gear (46) and spacer (28).
4. Install the primary housing (58) onto the
gear housing (60) with eight capscrews (32),
making sure not to damage the o-ring (59),
and torque them to specification (see page
27 of this manual).
5. Install the secondary gear set (41). .
Make sure to line up all three
planet gears in the secondary
gear set with the gear housing
and sun gear as it starts into
the housing
6. Install the secondary sun gear (45).
7. Install the inner thrust washer (43) onto the
input gear set (42). Insert the input gear set
(42) into the ring gear (22) making sure it is
against the thrust washer (43). Put the outer
thrust washer (43) in place and slide the
input shaft (39) through the sun gears and
output shaft (38). Let the input shaft
protrude out on the gear end so that all of
the spline is showing.
8. Put the cover (55) on and secure it with
eight capscrews (3), being careful not to
damage the o-ring (59). Install the
Intelliguard™ sensor (39) into the cover (55)
with three capscrews (44), again making
sure not to damage the o-ring (114), add
locktite and secure it with three capscrews.
(44)
Make sure the input shaft
engages the gear in
the Intelliguard™ correctly.

18
L. DRUM SECTION ASSEMBLY
1. After inspecting and replacing the necessary
parts, such as the drum bushings (31), drum
clutch (115). Install the drum (34) onto the
output shaft (38). This part is very heavy
and you will need the assistance of a hoist.
With the weight of the drum supported,
install the brake band assembly (66) along
with the bracket (73), capscrews (70), nuts
(71), and washers (72).
2. Install the brake band air cylinder (68),
making sure the rod of the air cylinder (68) is
going through the bracket on the brake band
(66). Secure it to the bracket (73) with the
clevis pin (99) and cotter key (100). Tighten
the adjusting nut on the air cylinder shaft
until there is not space between the drum
(34) and the brake band (66). Then, tighten
the jam nut to secure the adjusting nut.
3. Install the inner thrust collar (24) making
sure the half-moon slots are lined up with
the key slots in the output shaft (38). Tap
the three keys (94) into their slots in the
output shaft.
4. Align the coupler (30) with the keys (94) and
slide it onto the output shaft (38). Install the
sliding clutch (27) and yoke (67) onto the
coupler (30).
5. Install the outer thrust collar (53), aligning
the half moon slots with the keys (94).
Tightly hold the thrust collar (53) against the
keys and lock down the three set screws
(50).
6. Slide the brake housing (20) onto the output
shaft (38). (Continued on page 19)
The brake band may
need to be readjusted
once it’s in the field.
You may need to lower the
drum to align the holes in
the brake band with the
holes in the frame.

19
DRUM SECTION ASSEMBLYCONTINUED
7. Bolt the brake housing (20) loosely into both
frames (64, 65). Lower the drum so the
weight of the drum is supported by both the
brake and gear housings. The air line from
the brake band air cylinder can be attached
at this time.
8. Disengage the sliding clutch (27) so you can
turn the drum freely and tighten all bolts
through the frames to the proper torque
specification (see page 27 of this manual).
9. Turn the drum to make sure it is not binding.
10. If necessary, install the air cylinder (105)
and the air cylinder cover (91) to the brake
housing with four capscrews (69) and
spacers (97).
11. Install the bracket (90) to the brake housing
using four capscrews (29).
12. Attach the yoke (67) by installing clevis pins
(49) into the bracket (90) and clevis (48).
Install cotter keys (100) to clevis pins (49) to
secure their positions. Connect shop air to
the cylinder and apply air in both directions.
With the clutch fully engaged (air applied),
there should be slight movement on the
sliding clutch (27) in both directions. Adjust
clevis (48) and air cylinder jam nut
accordingly.

20
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. Install the bearing housing assembly that
contains parts 16 and 52 into the brake
housing.
3. Install the driver/clutch assembly onto the
Intelliguard shaft (39).
4. 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 six
friction discs are used.
Dip friction discs in lightweight
Non-EP oil before installation.
5. Install the piston (5) into the brake housing
(20) and gently tap it down until it is seated
making sure not to damage the o-rings (8,
10) or back-up rings (9, 11).
6. Install the springs (7) into the spring pockets
in the piston. If working in a horizontal
position, coat the bottom of each spring with
chassis lube to keep it in position.
7. Install the cover (2) onto the brake housing
(20) using four capscrews (3) making sure
the cover is correctly oriented. Then, draw it
down evenly, alternating between opposite
capscrews, being careful not to damage the
o-ring (6).
8. Check the brake release with a portable
hydraulic pump. Full release should be
obtained at 400psi, plus or minus 20psi.
Also, check the brake for proper operation
by applying 105psi to the brake port and
adapting a torque wrench to the Intelliguard
shaft. The torque in the payout should be
134 to 154 ft-lbs.