DESIGN SERIES 001

RUFNEK 100
AND
MODEL 80
SERVICE MANUAL
GENERAL INFORMATION .......................................................................................................................... 4
INTRODUCTION AND THEORY OF OPERATION ................................................................................................................. 4
ASSEMBLY NUMBER EXPLANATION ................................................................................................................................... 4
WINCH BREAK-IN .................................................................................................................................................................. 4

MODEL CODES ........................................................................................................................................... 5

MAINTENANCE............................................................................................................................................ 6
OIL LEVELS............................................................................................................................................................................ 7
BRAKE IDENTIFICATION AND ADJUSTMENT ...................................................................................................................... 8

DISASSEMBLY .......................................................................................................................................... 10
DRUM BRAKE DISASSEMBLY............................................................................................................................................. 10
ADJUSTABLE OIL BRAKE DISASSEMBLY.......................................................................................................................... 11
NON-ADJUSTABLE BRAKE DISASSEMBLY ....................................................................................................................... 12
RUFNEK BRAKE DISASSEMBLY......................................................................................................................................... 13
CLUTCH AND DRUM DISASSEMBLY.................................................................................................................................. 14
GEARBOX DISASSEMBLY................................................................................................................................................... 15
GEAR INSPECTION INSTRUCTIONS .................................................................................................................................. 16

ASSEMBLY ................................................................................................................................................ 17

GEARBOX ASSEMBLY ........................................................................................................................................................ 17

DRUM BRAKE ASSEMBLY .................................................................................................................................................. 18
ADJUSTABLE OIL BRAKE ASSEMBLY................................................................................................................................ 19
NON-ADJUSTABLE OIL BRAKE ASSEMBLY....................................................................................................................... 20
RUFNEK ADJUSTABLE OIL BRAKE ASSEMBLY ................................................................................................................ 21
CLUTCH AND DRUM ASSEMBLY........................................................................................................................................ 22

TROUBLESHOOTING................................................................................................................................ 23
BILL OF MATERIAL................................................................................................................................... 24
ADJUSTABLE BRAKE BILL OF MATERIAL ........................................................................................... 27
NON ADJUSTABLE BRAKE BILL OF MATERIAL .................................................................................. 27
RUFNEK BRAKE BILL OF MATERIAL..................................................................................................... 28
TORQUE SPECIFICATIONS CHART ........................................................................................................ 29
CLUTCH INSPECTION .............................................................................................................................. 30
ISOMETRIC VIEW ...................................................................................................................................... 31
ADJUSTABLE BRAKE, HYDRAULIC MOTOR, & CLUTCH POSITION INDICATOR VIEWS................ 32

SEL-0049-001.DOC
REV-0 JAN 2006
 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. Additionally, 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/

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.

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.

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.

Relief valves should be set to winch manufacturer’s specifications.

Insure that all PTO’s and drivelines are sized appropriately for the winch manufactures
speed and torque specifications.

2
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 can be equipped with two (2) forms of dynamic braking. The
worm brake is one method and is adjustable for pay-out load control. 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 that is not field adjustable.
The same method should be used to check this brake.

Operation:

• All winch controls must be well marked for function to avoid confusion.
• Insure that the PTO is disengaged when the winch is not in use.
• 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.

3
 GENERAL INFORMATION
INTRODUCTION AND THEORY OF OPERATION

The Tulsa worm gear winch is operated by turning the input of the worm using a
hydraulic motor or PTO driven sprocket and chain. The winch utilizes the adjustable,
spring applied, multiple disc oil brake that activates only during pay-out to provide
maximum efficiency during pay-in. The torque is transferred from the gearbox through
the drum shaft which is keyed to a mechanically actuated sliding clutch that, when
engaged, transfers the torque to the drum.

ASSEMBLY NUMBER EXPLANATION

This manual is for design series 001. 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

81370 001
WINCH BREAK-
BREAK-IN

Winches, like any other kind of machinery, require a “break-in” period 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 onto the winch. DO NOT run the winch
at high speeds when performing this operation. Make sure that the cable is unrolled in a
line (to prevent kinks) and SLOWLY inhaul the winch to install the cable.

DO NOT exceed one half rated load or one half rated line speed for the first thirty
minutes of operation. This will insure that the worm and gear have an opportunity to
wear in properly. Periodically, check the gearbox for temperature rises and allow the
winch to cool down between pulls. Worm gear winches are designed and intended for
intermittent duty application only; using them in extremely long pulls may generate
excessive heat and shorten the life of the winch.

4
 MODEL CODES

THE RUFNEK SERIES

WINCHES ARE ONLY
RN100 WM R F O M X AVAILABLE WITH LEFT
HAND GEARS.

Motor Type
Gear Type
1. Single Speed Gear Motor
W=Worm
2. Two Speed Gear Motor
P=Planetary
3. Single Speed Geroler Motor
Drive Type
4. Two Speed Geroler Motor
H=Hydraulic
5. Piston
M=Mechanical
6. Vane
Gearbox Position
X. No Motor
L=Left
R=Right Clutch Device
(viewed from rear of truck) M=Mechanical
Input Shaft Location A=Air
F=Front
Cable Spooling
R=Rear
O=Over Drum
X=Does not apply
U=Under Drum
(viewed from rear of truck)
(viewed from rear of truck)

M80 S L R F O D CL

Winch Type Motor Type

M=Mechanical CL-CharLynn
H=Hydraulic Motor Mount
G=Speed Reducer D=Direct Mount
No. of Worm Starts X=No Motor
S=Single
Cable Spooling
D=Double
T=Triple O=Over Drum
Worm Angle U=Under Drum
L=Left (viewed from rear of truck)
R=Right Input Shaft Location
Gearbox Location F=Front
L=Left R=Rear
R=Right X=Does not apply
(viewed from rear of truck) (viewed from rear of truck)

5
 MAINTENANCE
Tulsa Winch worm gear driven winches require regular maintenance to ensure safe
and reliable operation. Regular oil changes with the correct oil for the ambient
temperature conditions and an annual inspection of the wear components are strongly
recommended.
Maintenance Scheduling

The owner is to ensure proper inspection intervals, in compliance with the API RP
2D Section 4, ANSI B30.5, 5-2.3, or ANSI B30.7, 7-2.1, and will review winch usage
categories on a periodic basis. A qualified inspector should perform all maintenance
and inspections.

USE API RP 2D RECOMMENDED

(HRS PER INSPECTION SCHEDULE
MONTH)
0-10 PRE-USE, ANNUAL
11-50 PRE-USE, QUARTERLY
51+ PRE-USE, MONTHLY

Oil Maintenance

The oil in the gear section and the brake section should be changed every 1000 hrs or
6 months of normal usage. If your winch is mounted with a drum brake, do not fill the
brake with oil.

• 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 = 8 QTS

• Gearbox oil level inspection is achieved by removing the oil level inspection plug
and visually inspecting the oil level. Minimum oil level is to the bottom of the
threads of the inspection hole. Refer to the chart below for the recommended oil
type and grade for your application.

SAE 140W AGMA 7 EP

MOBIL SHC 626

MOBILUBE HD80W140

All oils must meet MIL-PRF2105E standards. Substitution from a reputable

manufacturer is allowed as long as type and grade are maintained.

6
 OIL LEVELS

GEARBOX
FILL/VENT

GEARBOX
OIL LEVEL

GEARBOX
OIL DRAIN

BRAKE
FILL/VENT
BRAKE
OIL DRAIN

BRAKE
OIL LEVEL

7
 BRAKE
BRAKE IDENTIFICATION AND ADJUSTMENT

In general, worm brakes on Tulsa winches should be set to hold the load you are
currently working with. Excessive brake torque will result in excessive heat generation
and brake wear. The best way to insure proper brake adjustment is to pull the cable
tight against the load and stop to ensure the brake holds. If it doesn’t, tighten the brake
slightly and try it again. If the brake doesn’t respond to adjustment the brake must be
serviced.

If the input to the winch is accessible and a torque wrench can be adapted to it, the
brake can be set with a torque wrench. The Model 80 brake is shipped from the factory
pre-set at 185 Ft.-Lbs.

ADJUSTABLE SHOE BRAKE

To tighten the brake, remove the two capscrews located in the set of holes in the top
and bottom of the brake cover. Loosen the two capscrews in the slotted holes and
rotate the brake clockwise.

The direction of braking can be changed by replacing the cam with the opposite version.
For detailed service instructions, contact your Tulsa Winch distributor or the factory.

ADJUSTABLE MULTIPLE DISC OIL BRAKE

This is the standard version of the multiple disc oil brake. This style of brake can be
adjusted by turning the hex adjuster counter-clockwise to increase brake and clockwise
to decrease brake. The direction of braking for all multiple disc brakes can be changed
by removing the cam clutch, turning it over, and re-installing it. For detailed service
instructions, contact your Tulsa Winch distributor or the factory.

If the input to the winch is accessible and a torque wrench can be adapted to it, the
brake can be set with a torque wrench. The RN100W brake is shipped from the factory
pre-set at 185 Ft.-Lbs.

8
 BRAKE IDENTIFICATION AND ADJUSTMENT CONTINUED

Some versions of the Model 80 winch are equipped with a non-adjustable multiple disc
oil brake. These winches can be identified by the warning on the cover.

NON-ADJUSTABLE MULTIPLE DISC OIL BRAKE

CAUTION DURING REMOVAL!

SPRING LOADED COVER!

These brakes require no regular adjustment. The direction of braking for all multiple disc
brakes can be changed by removing the cam clutch, turning it over, and re-installing it.
For detailed service instructions, contact your Tulsa Winch distributor or the factory.

______________________________________________________________________

RUFNEK ADJUSTABLE MULTIPLE DISC OIL BRAKE

This brake is the Rufnek version of the adjustable oil brake. This is the latest design of
the worm-driven winch brakes. This style of brake can be adjusted by turning the hex
adjuster counter-clockwise to increase brake and clockwise to decrease brake. The
direction of braking for all multiple disc brakes can be changed by removing the cam
clutch, turning it over, and re-installing it. For detailed service instructions, contact your
Tulsa Winch distributor or the factory.

If the input to the winch is accessible and a torque wrench can be adapted to it, the
brake can be set with a torque wrench. The RN100W brake is shipped from the factory
pre-set at 185 Ft.-Lbs.

9
 DISASSEMBLY
DRUM BRAKE DISASSEMBLY
1. Loosen the capscrews (31). 7. Inspect parts as follows, replace if
necessary:
2. Remove the capscrews (88) from the
cover (86). A. Inspect the brake shoes (98) for
wear. If the shoe linings are worn
3. Remove the cover (86) from the flush with the rivet heads, the
gearbox. shoes must be replaced.

4. Remove the brake shoes (98). B. Inspect the brake drum (95) for
severe wear or scoring.
5. Remove the nut (97) and washer
(96). C. Check the inside lower part of the
gearbox housing for the presence
6. Use the two threaded holes in the of oil. Replace the seal (37) if oil
brake drum (95) and a gear puller to is present
remove the brake drum.

If replacing the seal (37), first

drain the oil from the gearbox then
remove the capscrews (94) and
brake cover (93).

10
 ADJUSTABLE OIL BRAKE DISASSEMBLY

1. Drain the oil from the brake by 5. Remove the spring (10). Grasp the
removing the drain plug (21). brake driver (8) and remove the
brake components.
2. Loosen the spring tension inside the
brake by turning the adjusting 6. Inspect stator plates (16), friction
mechanism (22) clockwise until it discs (17), and retaining ring (7) for
stops. wear and replace them if necessary.

7. Noting the direction that the cam

clutch (6) is installed, inspect it for
Extreme care should be taken wear. Replace if necessary.
when removing the cover of the
brake housing. The cover
compresses the spring which is
used to set the brake, thus the Failure to re-install the clutch in
cover is spring loaded against the the correct orientation will result
cover screws. in the brake engaging in the
opposite direction.
3. Loosen and remove the capscrews
(13) and washers (14) from the brake 8. If necessary, remove the reaction
cover (20). If needed, rotate the housing (2) and replace the oil seal
adjusting mechanism counter- (19).
clockwise to allow the spring to apply
force to the cover.

4. Remove the adjusting mechanism

(22) from the brake cover (20) and
inspect the o-ring (23), replace it if
necessary.

FOR CORRECT PART

SEQUENCE NUMBERS
REFER TO PAGE 27 FOR
ADJUSTABLE BRAKE
BILL OF MATERIAL

11
 NON-
NON-ADJUSTABLE BRAKE DISASSEMBLY

1. Place a container underneath the 4. Inspect the stator plates (12), friction
brake to catch the oil when the cover discs (13), and retaining ring (11) for
is removed. wear and replace them if necessary.

5. Noting the direction that the cam

clutch (8) is installed, inspect it for
Extreme care should be taken wear. Replace if necessary.
when removing the cover of the
brake housing. The cover
compresses the spring which is
used to set the brake, thus the Failure to re-install the clutch in
cover is spring loaded against the the correct orientation will result
cover screws. in the brake engaging in the
opposite direction.
2. Evenly loosen and remove the
capscrews (20) and washers (21) If necessary, remove the reaction
from the brake cover (17) to dislodge housing (3) and replace the oil seal
the cover. (16).

3. Remove the spring (14), then grasp

the brake driver (9) and remove the
brake components.

FOR CORRECT PART

SEQUENCE NUMBERS
REFER TO PAGE 28 FOR
NON-ADJUSTABLE BRAKE
BILL OF MATERIAL

12
 RUFNEK ADJUSTABLE
ADJUSTABLE OIL BRAKE DISASSEMBLY

1. Remove the bottom drain plug (9) to 5. Inspect parts as follows, replace if
drain oil from brake. necessary:

2. Loosen the spring tension inside the A. Inspect the friction discs (19) for
brake by rotating the adjusting uneven or excessive wear.
mechanism (6) clockwise until it Friction discs should measure no
stops. less than .055-in thick.

B. Inspect the stator plates (20) for

warpage or excessive wear.
Extreme care should be taken
when removing the brake cover. C. Inspect the spring (13) for
the cover is spring loaded against damage or discoloration.
the cover screws.
D. Cam clutch (25) should be free of
3. Evenly remove the capscrews (11) debris and have all cams intact.
and washers (12) from the brake
cover (7).

4. Remove the spring (13) and retaining If replacing the cam clutch (25),
ring (21), then remove the brake take note of the direction it
driver (23) along with the brake locks up for reassembly.
components (19, 20, 21, 22, 23, 25,
26, 27, and 28 ). E. Check the coupler (10) for signs
of pitting, spalling, or excessive
wear.

FOR CORRECT PART

SEQUENCE NUMBERS
REFER TO PAGE 28 FOR
RUFNEK ADJUSTABLE
BRAKE BILL OF MATERIAL

13
 CLUTCH AND DRUM DISASSEMBLY

1. Remove the cotter keys (20) and 7. Remove the brake band assembly
clevis pins (19) holding the rod (5) by removing the capscrews (27),
assembly (24, 28, 38) in place. nuts (24), and washers (25)
Remove the rod assembly. attaching the brake band to the
frame.
2. Remove the arms (18) by removing
the capscrews (43), nuts (17), and 8. Slide the drum (14) off of the output
washers (16) holding the arms in shaft (78), using an overhead hoist.
place.
9. Inspect parts as follows, replacing
3. Loosen the tension on the brake them if necessary:
band (5) by loosening the nuts on the
rod (29), then remove the line shafts A. Inspect the thrust washers (6) for
(15) by loosening the set screws in excessive wear or damage.
the collars (40) and the set screws
(22) in the control arms (21 & 39). B. Inspect the bushing (12 & 23) for
excessive wear or damage.
4. Remove the capscrews (61), nuts
(63), and washers (62) connecting C. Inspect the keys (79) for
the end bracket (32) to the frames excessive wear or damage.
(64 & 67).
D. Inspect the drum clutch (8) and
5. Remove the end bracket (32) and sliding clutch (7) for wear. See
yoke assembly (items 4, 31, 36, 41, page 30 this manual for Clutch
42) or the clutch position indicator Inspection.
assembly (100). Remove the thrust
washer (6). E. Inspect the brake band assembly
(5) and verify that the band and
lining is at least .225-in thick.
6. Remove the sliding clutch (7), keys
(79), and the other thrust washer (6).

14
 GEARBOX
GEARBOX DISASSEMBLY

1. Supporting the end of the output sliding off the bearing retainer (59),
shaft (78) with a hoist, remove the along with the two sets of angular
housing cover (80) by removing bearings (58). Finally, remove the
capscrews (1 & 43), nuts (17 & 34), third set of bearings (91).
and washers (16 & 35).

2. Use the hoist to lift the output shaft

(78), bushings (77), keys (76), and If the brake has not been removed,
gear (assembled items 24, 25, 71, see brake disassembly on pages
72, 73, 74, and 75) out of the 10-13 of this manual.
housing (61).
7. Inspect parts as follows, replacing
3. Remove the bushing (77) from the them if necessary:
output shaft (78).
A. Inspect the inner carriers (74) for
4. Remove the gear (71) from the damage.
carriers (74) by removing the sixteen
capscrews (75), nuts (24), and B. Inspect the gear (71) for
washers (25), then pull the carrier excessive wear or damage. See
(74) off of the shaft (78). Finally, page 16 for detailed instructions.
remove the spacer (73), carrier (74),
and keys (76). C. Inspect the keys (76) and
bushings (77) for damage.
5. Remove the worm assembly
(assembled items 58, 59, 60, and 91) D. Inspect the worm (60) for
from the housing by removing either excessive wear or signs of heat
the motor (99) and motor adapter checking or cracks.
(93) or the end cap (59), depending
on type of drive. From the brake E. Inspect the bearings (58 & 91)
end, push the worm assembly out of and seals (37 & 58) for excessive
the housing (90). wear or damage.

6. Disassemble the worm by removing

the nut (54) and washer (55) then

15
 GEAR INSPECTION INSTRUCTIONS

LAND

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.

16
 ASSEMBLY
GEARBOX
GEARBOX ASSEMBLY

1. Press the angular bearings (58) into eight capscrews (53), using gasket
the bearing retainer (59), then slide (51). Install the key (65) into the
the bearing retainer and bearings worm (60) shaft.
onto the worm (60) and secure with
nut (54) and washer (55). 3. Install the keys (76) into the output
shaft (78).

4. Slide the carrier (74) over the keys

When installing the two angular (76). Install the spacer (73) using
bearings, it is imperative that they two pins (72). Slide the gear (71)
are installed with the surface text and the other carrier (74) onto the
facing the outside of the housing. shaft and secure with sixteen
capscrews (75), nuts (24), and
2. For winches driven by a hydraulic washers (25).
motor:
5. Install the assembled gear onto the
Install the motor adapter (103) and shaft (78). Slide the bushings (77)
worm assembly with eight capscrews onto both ends of the shaft.
(104), using gasket (68). Attach the
motor (99) with four capscrews 6. Install the output shaft assembly into
(101), using gasket (102). the housing (90).

For winches driven by a PTO 7. Install both gaskets (81) onto the
sprocket and chain: housing (90). Attach the cover (80)
to the housing, using capscrews
Press a new oil seal (48) into the end (1 & 43), nuts (17 & 34), washers
cap (50). Install the worm assembly (16 & 35), using gaskets (81).
into the gearbox (90), using gasket
(68). Secure the end cap (50) with

17
 DRUM BRAKE ASSEMBLY

1. Press the oil seal (37) into the end 3. If removed, reattach the cam (85) to
cap (93). Install the gasket (92), and the brake cover (86) using two
attach the end cap (93) to the capscrews (31) and washers (87).
gearbox with six capscrews (94),
using gasket (92). 4. Install the brake cover (86), cam
(85), and brake shoes (98) into the
2. Install the brake drum (95) and key gearbox.
(89) onto the worm shaft (60).
Secure the brake drum with the nut 5. Secure the brake cover (86) using
(97) using washer (96). Bend two eight capscrews (88).
tabs of the washer (96) over the flats
of the nut (97). 6. Adjust the brake using the procedure
on page 8 of this manual.

18
 ADJUSTABLE OIL BRAKE ASSEMBLY
ASSEMBLY

1. Press the oil seal (19) into the 4. Install the spring (10) and then press
reaction housing (2), then mount the the adjusting mechansim assembly
reaction housing to the gearbox with (items 9, 22, 23) into the brake cover
six capscrews (12), using a gasket (20).
(18).
5. Attach the brake cover (20) with
2. Install the key (1), coupler (5), and eight capscrews (13) and washers
clutch/driver assembly (3, 6, 7, 8), (14), using a gasket (15).
onto the worm shaft (57).
6. Fill the gearbox and brake with the
3. Install the retaining ring (11) into the proper oil. Refer to the winch
reaction housing (2), then install the maintenance section of this manual
stator plates (16) and friction discs for oil type and amounts.
(17) in the correct stack up, as
shown below.

FOR CORRECT PART

SEQUENCE NUMBERS
REFER TO PAGE 27 FOR
ADJUSTABLE BRAKE
BILL OF MATERIAL

19
 NON-
NON-ADJUSTABLE OIL BRAKE ASSEMBLY
1. Press the oil seal into the reaction 4. Install the spring (14) then press the
housing (3), then mount the reaction washer (16) into the brake cover
housing to the gearbox with six (17).
capscrews (5), using a gasket (2).
5. Secure the brake cover (17) with
2. Install the key (4), coupler (6), and eight capscrews (20) and washers
clutch/driver assembly (7, 8, 9, and (21), using a gasket (15).
10), onto worm shaft (60).
6. Fill gearbox and brake with proper
3. Install the retaining ring (11) into the oil. Refer to winch maintenance
reaction housing (3), then install the section of this manual for oil type and
stator plates (12) and friction discs amounts.
(13) in the correct stack up, as
shown below.

FOR CORRECT PART

SEQUENCE NUMBERS
REFER TO PAGE 27 FOR
NON-ADJUSTABLE BRAKE
BILL OF MATERIAL

20
 RUFNEK
RUFNEK ADJUSTABLE OIL BRAKE ASSEMBLY

1. Press the oil seal (1) into the reaction brake cover (7) and attach the brake
housing (2). Attach the reaction cover to the gearbox with eight
housing to the gearbox with eight evenly installed capscrews (11) and
capscrews (16) using gasket (17). washers (12).

2. Install the key (15) and coupler (10) 6. Install the drain plug (9) into the
onto the worm. Next, install the bottom of the brake cover (7).
clutch/driver assembly (Items 21, 22,
23, 25, 26, 27, and 28), onto the 7. Fill gearbox and brake with proper
coupler (10). oil. Refer to winch maintenance
section of this manual for oil type and
3. With the retaining ring (22) on the amounts.
clutch driver (23). Install the stator
plates (20) and friction discs (19), in 8. Adjust the brake using the procedure
the correct layout as shown below. on page 9 of this manual.

4. Install the spring (13).

5. Install the adjusting mechanism

assembly (items 5, 6, and 8) into the
FOR CORRECT PART
SEQUENCE NUMBERS
REFER TO PAGE 28 FOR
RUFNEK OIL BRAKE
BILL OF MATERIAL

21
 CLUTCH AND DRUM ASSEMBLY

1. Install bushings (12) into drum (14). 4. Install the end bracket (32) and the
Install the drum (14) onto the output yoke assembly or clutch position
shaft (78). indicator assembly (100) onto the
output shaft (78) and mount it to the
2. Slide the thrust washer (6) onto the frame using four capscrews (61),
output shaft (78). Install the keys nuts (63), and washers (62).
(79) into the output shaft.
5. Install the end cap (3) and bushing
3. Install the clutch indicator kit (100) (23) and secure them with four
onto the sliding clutch (7) and slide capscrews (1), nuts (34), and
the clutch over the keys (79). washers (35).

CLUTCH POSITION INDICATOR ADJUSTMENT

(FOR RUFNEK WINCHES ONLY)

Make sure that the sliding clutch (7) is fully engaged and that the yoke assembly (100)
is not binding on the drum clutch. The lugs of the 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 device.

Tighten the jam nut against the clutch bracket to secure the adjustment.

Test the switch by fully engaging, then disengaging, the clutch. The warning device
should activate while disengaging the clutch pivoting no more than 3°.

FIG.-1 FIG.-2 FIG.-2

FIG.-1
7

100

NUT

SWITCH

22
 TROUBLESHOOTING
FAILURE PROBABLE CAUSE
Clutch handle won’t latch a) Clutch jaws aren’t aligned. Align the
jaws by rotating drum.

b) Damaged yoke or linkage. Replace the

yoke or clutch
Oil leaks from housing a) Seal damaged or worn. Replace the
seal(s).

b) Too much gearbox oil. Drain excess

oil.

c) Gasket could be worn. Replace the

gasket.
Load drifts a) The brake is out of adjustment or worn.
Adjust brake until load doesn’t drift.
Replace the 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 vent in the a) Damaged motor shaft seal. Replace
gearbox the seal.
Winch won’t pick up heavy loads. a) Too much cable on the drum. Use the
snatch block or remove some cable
from the drum.

b) System pressure too low. Increase the

hydraulic system pressure.

c) Winch not broke-in. Run winch at half

of rated load for several pulls.

23
 BILL OF MATERIAL
BOM DATED SEPTEMBER 2005
SEQ QTY P/N DESCRIPTION
1 8 20886 CAPSCREW
2 5 21128 GREASE ZERK
3 1 20579 END CAP
4 1 20129 BRACKET
5 1 939310 BRAKE BAND ASSEMBLY
6 2 20603 WASHER
7 1 20591 CLUTCH
8 1 23600 CLUTCH
9 2 21214 NUT
10 1 21180 U BOLT
11 6 21644 CAPSCREW
12 2 21360 BUSHING
13 5 20517 PIN
14 1 33449 DRUM
15 2 20404 SHAFT
16 13 20526 WASHER
17 12 20271 NUT
18 2 20070 CONTROL ARM
19 3 939243 PIN
20 3 20514 COTTER PIN
21 1 20648 CONTROL ARM
22 6 20193 SET SCREW
23 1 20599 BUSHING
24 23 20267 NUT
25 20 20518 WASHER
26 2 20913 WASHER
27 2 20311 CAPSCREW
28 3 20054 CLEVIS
29 1 939251 ROD
30 3 20521 NUT
31 5 20522 CAPSCREW
32 1 31668 BRACKET
33 1 20958 SPRING
34 8 20274 NUT
35 8 20520 LOCKWASHER
36 1 20593 YOKE
37 1 20775 OIL SEAL
38 1 21164 ROD
39 1 20072 CONTROL ARM
40 4 20230 COLLAR
41 2 24724 SNAP RING
42 1 20116 PIN
43 12 20276 CAPSCREW
44 1 20607 BRACKET
45 4 20105 KEY
46 1 20278 CAPSCREW
47 1 20320 WASHER

24
 BILL OF MATERIAL CONTINUED
SEQ QTY P/N DESCRIPTION
48 1 20621 OIL SEAL
49 2 20266 CAPSCREW
50 1 20583 COVER
51 3 20637 GASKET
52 -- -- OMIT
53 8 30204 CAPSCREW
54 1 20625 NUT
55 1 939232 WASHER
56 -- -- OMIT
57 -- -- OMIT
58 2 20620 BEARING
59 1 20581 HOUSING
60a 1 20618 LEFT HAND MECHANICALLY DRIVEN WORM
60b 1 20534 RIGHT HAND MECHANICALLY DRIVEN WORM
60c 1 40695 LEFT HAND HYDRAULICALLY DRIVEN WORM
60d 1 40694 RIGHT HAND HYDRAULICALLY DRIVEN WORM
60e 1 44075 RUFNEK MECHANICALLY DRIVEN WORM
60f 1 44077 RUFNEK HYDRAULICALLY DRIVEN WORM
61 8 20650 CAPSCREW
62 8 20652 WASHER
63 8 20653 NUT
64 1 25731 LEFT FRAME
65 1 20314 KEY
66 3 20286 PLUG
67 1 25730 RIGHT FRAME
68 1 939263 GASKET
69 -- -- OMIT
70 -- -- OMIT
71a 1 20619 LEFT GEAR
71b 1 20538 RIGHT GEAR
72 2 164056 PIN
73 1 20569 SPACER
74 2 22458 CARRIER
75 16 23884 CAPSCREW
76 3 20600 KEY
77 2 20546 BUSHING
78a 1 25729 OUTPUT SHAFT (EXTENDED)
78b 1 32715 OUTPUT SHAFT (FLUSH)
79 3 20608 KEY
80a 1 44036 RUFNEK GEARBOX COVER
80b 1 20540 GEARBOX COVER
81 2 20610 GASKET
82 1 29311 BUSHING
83 1 32789 BUSHING
84 1 13050 BREATHER
85a 1 20602 LEFT HAND CAM
85b 1 20597 RIGHT HAND CAM
86 1 20595 COVER
87 2 20617 WASHER
88 8 20289 CAPSCREW

25
 BILL OF MATERIAL CONTINUED
SEQ QTY P/N DESCRIPTION
89 1 20314 KEY
90 1 20536 HOUSING
91 1 20776 BEARING
92 1 20117 GASKET
93 1 939296 END CAP
94 6 939261 CAPSCREW
95 1 20542 BRAKE DRUM
96 1 20313 WASHER
97 1 20312 NUT
98 2 939311 BRAKE SHOE ASSEMBLY
99a 1 41412 MOTOR (57.4 CUBIC INCH DISPLACEMENT)
99b 1 40487 MOTOR (40.6 CUBIC INCH DISPLACEMENT)
100 1 4360 YOKE ASSEMBLY WITH CLUTCH POSITION INDICATOR
101 4 28212 CAPSCREW
102 1 40424 GASKET
103 1 40692 MOTOR ADAPTER
104 8 40705 CAPSCREW

26
 ADJUSTABLE BRAKE BILL OF MATERIAL
SEQ QTY P/N DESCRIPTION
1 1 33420 KEY
2 1 32946 REACTION HOUSING
3 1 42695 RETAINING RING
4a 1 12208 BUSHING
4b 1 13050 BREATHER
5 1 32942 COUPLER
6 1 33407 CAM CLUTCH
7 1 31076 RETAINING RING
8 1 3687 DRIVER
9 1 42692 SPRING PLATE
10 1 32949 SPRING
11 1 32950 RETAINING RING
12 6 939256 CAPSCREW
13 8 939261 CAPSCREW
14 8 20526 WASHER
15 1 32951 GASKET
16 10 32952 STATOR PLATE
17 6 32953 FRICTION DISC
18 1 20117 GASKET
19 1 20775 OIL SEAL
20 1 42690 BRAKE COVER
21 2 32220 PIPE PLUG
22 1 41406 ADJUSTING MECHANISM
23 1 41411 O-RING

NON ADJUSTABLE BRAKE BILL OF MATERIAL

SEQ QTY P/N DESCRIPTION
1 1 20775 OIL SEAL
2 1 20117 GASKET
3 1 32946 REACTION HOUSING
4 1 33420 KEY
5 6 939256 CAPSCREW
6 1 32942 COUPLER
7 -- -- OMIT
8 1 33407 CAM CLUTCH
9 1 3687 DRIVER
10 1 31076 RETAINING RING
11 1 32950 RETAINING RING
12 9 32952 STATOR PLATE
13 6 32953 FRICTION DISC
14 1 32949 SPRING
15 1 32951 GASKET
16 1 32944 WASHER
17 1 32941 BRAKE COVER
18 1 13050 BREATHER
19 1 20286 PIPE PLUG
20 8 939261 CAPSCREW
21 8 20526 WASHER

27
 RUFNEK BRAKE BILL OF MATERIAL
SEQ QTY P/N DESCRIPTION
1 1 20775 OIL SEAL
2 1 32946 REACTION HOUSING
3 1 12208 BUSHING
4 1 13050 BREATHER
5 1 41411 O-RING
6 1 41406 ADJUSTING MECHANISM
7 1 43974 BRAKE COVER
8 1 42692 SPRING PLATE
9 2 21684 PLUG
10 1 44139 COUPLER
11 8 939261 CAPSCREW
12 8 20526 WASHER
13 1 32949 SPRING
14 1 44146 O-RING
15 1 25519 KEY
16 6 939256 CAPSCREW
17 1 20117 GASKET
18 1 44075 REPLACEMENT WORM (MECHANICAL INPUT)
19 7 32953 FRICTION DISC
20 12 32952 STATOR PLATE
21 1 32950 RETAINING RING
22 1 42695 RETAINING RING
23 1 44140 DRIVER
24 -- -- OMIT
25 1 41759 CLUTCH
26 2 41743 BUSHING
27 1 26980 RETAINING RING
28 2 41723 RACE

28
 TORQUE SPECIFICATIONS
SPECIFICATIONS CHART
Dry Plated Lubricated Dry Plated Lubricated
SAE SAE SAE SAE SAE SAE
Grade 5 Grade 5 Grade 5 Grade 8 Grade 8 Grade 8
Torque Torque Torque
Torque Torque Torque
Nominal Size *(Ft- *(Ft- *(Ft-
*(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs)
Lbs) Lbs) Lbs)
1/4 20 8 6 5 12 9 7
1/4 28 10 7 6 14 10 8
5/16 18 17 13 10 25 18 15
5/16 24 19 14 11 27 20 16
3/8 16 31 23 19 44 33 26
3/8 24 35 26 21 49 37 30
7/16 14 49 37 30 70 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 7 794 596 475 1288 966 772
1-1/8 12 890 668 534 1444 1083 866
1-1/4 7 1120 840 672 1817 1363 1090
1-1/4 12 1241 930 745 2012 1509 1207
T = BOLT TORQUE (LB. FT.) T = (KWD) / 12
K = TORQUE COEFFICIENT (K = 0.20 DRY K = 0.15 PLATED K = 0.12 LUBRICATED)
W = PRELOAD TENSION
D = NOMINAL BOLT SIZE (IN.) * ALL TORQUE VALUE TOLERANCES ARE ± 5%

29
CLUTCH INSPECTION

30
 ISOMETRIC VIEW

FOR ADJUSTABLE OIL

BRAKE AND HYDRAULIC
MOTOR, SEE PAGE 32

31
 ADJUSTABLE BRAKE, HYDRAULIC
HYDRAULIC MOTOR,
MOTOR, & CLUTCH POSITION
POSITION INDICATOR VIEWS

MOTOR VIEW

ADJUSTABLE
OIL BRAKE

CLUTCH POSITION
INDICATOR KIT

32