Tulsa RUFNEK 10 User manual

SEL-0043-001.DOC
REV-0 July 2020
RUFNEK 10
AND
MODEL 1138
SERVICE MANUAL
GENERAL INFORMATION .......................................................................................................................... 4
INTRODUCTION AND THEORY OF OPERATION.................................................................................................................. 4
ASSEMBLY NUMBER EXPLANATION ................................................................................................................................... 4
WINCH BREAK-IN .................................................................................................................................................................. 4
MODEL CODE .............................................................................................................................................. 5
MAINTENANCE............................................................................................................................................ 6
OIL LEVELS............................................................................................................................................................................ 7
BRAKE ADJUSTMENT ........................................................................................................................................................... 8
DISASSEMBLY ............................................................................................................................................ 8
BRAKE DISASSEMBLY .......................................................................................................................................................... 8
CLUTCH AND DRUM DISASSEMBLY .................................................................................................................................... 9
GEARBOX DISASSEMBLY..................................................................................................................................................... 9
GEAR INSPECTION INSTRUCTIONS .................................................................................................................................... 10
ASSEMBLY ................................................................................................................................................ 11
GEARBOX ASSEMBLY .......................................................................................................................................................... 11
BRAKE ASSEMBLY................................................................................................................................................................ 11
CLUTCH AND DRUM ASSEMBLY .......................................................................................................................................... 12
TROUBLESHOOTING................................................................................................................................ 13
RUFNEK 10 BILL OF MATERIAL .............................................................................................................14
TORQUE SPECIFICATIONS CHART ........................................................................................................ 16
CLUTCH INSPECTION .............................................................................................................................. 17
RUFNEK 10 ISOMETRIC DRAWING ........................................................................................................ 18
DESIGN SERIES 001

2
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.
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.
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.

3
Operator:
Must read and understand the operating and service manual.
Both the SERVICE MANUAL and OPERATING 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.

4
81276 001
ASSEMBLY # SERIES
DESIGN
GENERAL INFORMATION
GENERAL INFORMATIONGENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION AND THE
INTRODUCTION AND THEINTRODUCTION AND THE
INTRODUCTION AND THEORY OF OPERATION
ORY OF OPERATIONORY OF OPERATION
ORY OF OPERATION
The Rufnek series 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 an
adjustable 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 EXPL
ASSEMBLY NUMBER EXPLASSEMBLY NUMBER EXPL
ASSEMBLY NUMBER EXPLANATION
ANATIONANATION
ANATION
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.
WINCH
WINCH WINCH
WINCH BREAK
BREAKBREAK
BREAK-
--
-IN
ININ
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 onto the winch. DO NOT run the winch
at high speeds when performing this operation. Make sure that the cable is payed-out in
a straight line (to prevent kinks) and SLOWLY pay-in 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.

5
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
RN10 W H R F M O1
MODEL CODE
MODEL CODEMODEL CODE
MODEL CODE

6
MOBIL SHC 626
MOBILUBE HD80W140
SAE 140W AGMA 7 EP
MAINTENANCE
MAINTENANCEMAINTENANCE
MAINTENANCE
Tulsa Rufnek series worm gear winches require regular maintenance to ensure safe
and reliable operation. Routine oil changes with the correct oil for the ambient
temperature conditions and a regular inspection of the wear components is strongly
recommended.
Maintenance Scheduling
The owner is to insure 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.
Oil Maintenance
The oil should be changed every 1000 hrs or 6 months of 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 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 oil level hole (see page 7 for oil level hole location). Refer to the
chart below for the recommended oil type and grade for your application.
All oils must meet MIL-PRF2105E standards. Substitution from a reputable manufacturer is allowed as long as type
and grade are maintained.
USE
(HRS PER MONTH)
API RP 2D RECOMMENDED
INSPECTION SCHEDULE
0-10 PRE-USE, ANNUAL
11-50 PRE-USE, QUARTERLY
51+ PRE-USE, MONTHLY
OIL CAPACITY = .75 QTS

7
OIL LEVELS
OIL LEVELSOIL LEVELS
OIL LEVELS
GEARBOX
OIL LEVEL
GEARBOX
FILL/VENT
GEARBOX
OIL DRAIN

8
MAINTENANCE
MAINTENANCE MAINTENANCE
MAINTENANCE CONTINUED
CONTINUEDCONTINUED
CONTINUED
BRAKE ADJUSTMENT
BRAKE ADJUSTMENTBRAKE ADJUSTMENT
BRAKE ADJUSTMENT
This brake uses a one way cam clutch
(49) allowing free spooling in the in-haul
direction and engages in the payout
direction. To increase the brake torque,
follow the steps listed below.
1. Loosen the locknut (53).
2. Increase the brake torque by turning
the adjusting screw (52) clockwise.
3. Tighten the locknut (53) after the
brake adjustments are completed.
The brake should be adjusted to hold
no more than the winch rating. If the
brake does not respond to
adjustment, the brake must be
disassembled and inspected per
brake disassembly section of this
manual.
Excessive brake torque can cause
over heating and premature wear.
D
DD
DISASSEMBLY
ISASSEMBLYISASSEMBLY
ISASSEMBLY
BRAKE DISASSEMBLY
BRAKE DISASSEMBLYBRAKE DISASSEMBLY
BRAKE DISASSEMBLY
1. Remove the bottom plug (34) to
drain the oil.
2. Loosen the locknut (53) and brake
adjusting screw (52) to reduce spring
force on brake housing (45).
3. Remove the capscrews (56) from the
brake housing (45).
4. Remove the brake housing (45),
thrust washer (51), and spring (50)
from the gearbox.
5. Remove the stator plates (48),
friction discs (47), brake hub (46),
spacer (55), and cam clutch (49)
from the worm (30).
Make sure to note the direction
that the cam clutch and brake hub
are installed. They must be re-
installed the same way.
6. Inspect parts as follows, replace if
necessary:
A. Inspect the friction discs (47) for
excessive wear. Friction discs
should measure no less than
.065-in thick.
B. Inspect the flat surfaces of the
brake hub (46), stator plates (48),
and thrust plate (51) for warpage,
excessive wear, or other damage.
C. Examine the spring (50) for any
discoloration.
D. The cam clutch (49) should be
free of any debris and have all
rollers intact. If cam clutch needs
to be replaced, a new cam clutch
should be carefully pressed into
the brake hub (46).

9
CLUTCH AND DRUM
CLUTCH AND DRUMCLUTCH AND DRUM
CLUTCH AND DRUM DISASSEMBLY
DISASSEMBLY DISASSEMBLY
DISASSEMBLY
1. Remove the four capscrews (12),
nuts (15), and washers (16)
attaching the end bracket (1) to the
frames (13).
2. Remove the end bracket (1), lever
assembly (17), sliding clutch (24),
and keys (14) from the output shaft
(3).
3. Remove the thrust washer (27).
4. With the support of a hoist, remove
the drum (2).
5. Inspect parts as follows, replace if
necessary:
A. Inspect the bushing (19) in the
end bracket (1) for excessive
wear.
B. Inspect the lever assembly (17),
sliding clutch (24), keys (14), and
thrust washer (27) for excessive
wear. See page 14 for clutch
inspection.
C. Inspect the bores of the drum (2)
for excessive wear or damage.
D. Check the drag brake (8) for
excessive wear.
E. Inspect the oil seal (25) for any
leaks.
GEARBOX
GEARBOXGEARBOX
GEARBOX DISASSEMBLY
DISASSEMBLY DISASSEMBLY
DISASSEMBLY
1. Remove the brake from the gearbox.
See brake disassembly section of
this manual.
2. Remove either the motor (23) or the
end cap (58) (depending on type of
drive) by removing two capscrews
(38).
3. Remove the snap ring (32) from the
brake end of the worm.
4. From the brake end, push the worm
while rotating it in order to remove
the worm from the gearbox.
5. Remove the cover (6) from the
gearbox by removing the four
capscrews (11).
6. Remove the thrust washer (27) and
gear (29).
If the bushing in the gearbox
needs to be replaced, a complete
teardown is necessary.
7. Inspect parts as follows, replace if
necessary:
A. Inspect the worm (30) for
excessive wear, signs of heat
checking, or cracks.
B. Inspect the bearings (33) for
excessive wear or damage.
C. Inspect the thrust washers (27),
bushing (26), and gear (29) for
excessive wear.
D. Inspect the keys (28) and output
shaft (3) for damage.

10
G
GG
GEAR INSPECTION INSTRUCTIONS
EAR INSPECTION INSTRUCTIONSEAR INSPECTION INSTRUCTIONS
EAR 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

11
ASSEMBLY
ASSEMBLYASSEMBLY
ASSEMBLY
GEARBOX
GEARBOXGEARBOX
GEARBOX ASSEMBLY
ASSEMBLY ASSEMBLY
ASSEMBLY
1. Install the bushings (26) into the
gearbox (4) and cover (6).
2. Install the thrust washer (27) and
keys (28) onto the output shaft (3).
Slide the gear (29) over the keys (28)
and against the thrust washer (27).
Slide the other thrust washer (27)
onto the output shaft (3).
3. Install the cover (6) using the four
capscrews (11), being careful not to
damage the o-ring (10).
4. Install one bearing (33) and retaining
ring (32) onto the end of the worm
(30), then install the worm (30) into
the gearbox (4) engaging the gear
(29) as you push it through. Once
the worm (30) is in place, install the
other bearing (33) and retaining ring
(32) onto the worm (30).
5. If your winch uses mechanical input,
install a new oil seal (59) into the end
cap (58). Install the end cap with two
capscrews (38).
6. If your winch uses a hydraulic motor.
Install the motor (23) and o-ring (35).
7. Fill to the proper oil level with the
recommended lubricant. See
maintenance section of this manual
on page 6.
BRAKE ASSEMBLY
BRAKE ASSEMBLYBRAKE ASSEMBLY
BRAKE ASSEMBLY
1. Insert the following parts into the
brake housing (45) in this order:
•Thrust washer (51)
•Spring (50)
•Stator plate (48)
•Friction disc (47)
•Cam clutch/brake
hub assembly (46,49)
•Friction disc (47)
•Stator plate (48)
•Brake spacer (55)
•Gasket (21)
2. Install the brake assembly onto the
gearbox (4) with two capscrews (56).
3. Tighten the brake adjustment screw
(52) until tension from the spring (50)
is felt. See brake adjusting section
of this manual.
Factory preset is 8 ft/lbs @ worm
input
4. Fill to the proper oil level with the
recommended lubricant. See
maintenance section of this manual
on page 6.

12
CLUTCH AND DRUM
CLUTCH AND DRUMCLUTCH AND DRUM
CLUTCH AND DRUM ASSEMBLY
ASSEMBLY ASSEMBLY
ASSEMBLY
1. If necessary, replace the oil seal (25)
in the gearbox (4)
2. Place some grease into the pockets
located on the back of the gearbox
(4) and install the springs (9) and
drag brakes (8). The grease should
hold them in place.
3. Grease the inside of the drum bore
and the output shaft. Install the drum
(2) and thrust washer (27) onto the
output shaft (3).
4. Install the sliding clutch (24), lever
(17), and end bracket (1).
5. Attach the end bracket (1) to the
frames using four capscrews (12),
nuts (15), and washers (16).
6. Install the plug (34) into the bottom of
the gearbox (4). Fill to the proper oil
level with the recommended lubricant
(see page 6 of this manual).

13
TROUBLESHOOTING
TROUBLESHOOTINGTROUBLESHOOTING
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
damaged parts.
Oil leaks from housing a) Seal damaged or worn. Replace the
seal(s).
b) Too much gearbox oil. Drain excess
oil.
Load drifts down a) Oil-cooled brake 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 flat surface.
b) Clutch not disengaged. Disengage the
clutch.
Cable birdnests when clutch is
disengaged.
a) Drag brakes are worn. Replace the
drag brakes.
Hydraulic fluid leaks from the gearbox a) Damaged motor shaft seal. Replace
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.

14
RUFNEK
RUFNEK RUFNEK
RUFNEK 1
11
10 BILL OF MATERIAL
0 BILL OF MATERIAL0 BILL OF MATERIAL
0 BILL OF MATERIAL
81276001-BOM SEPTEMBER 2005
ITEM QTY P/N DESCRIPTION
1 1 41207 END BRACKET
2 1 41190 DRUM
3 1 41193 OUTPUT SHAFT
4 1 41188 HOUSING
5 1 12208 BUSHING
6a 1 44046 RUFNEK 10W COVER
6b 1 41192 MODEL 1138 COVER
7 1 23582 SET SCREW
8 3 25692 DRAG BRAKE
9 3 25774 SPRING
10 1 40547 O-RING
11 4 40407 CAPSCREW
12 8 10381 CAPSCREW
13 2 41197 FRAME
14 2 25762 KEY
15 8 20521 NUT
16 8 20518 LOCKWASHER
17 1 4069 LEVER ASSEMBLY
17-1 1 41185 YOKE
17-2 1 20296 PIN
17-3 1 20299 SPRING
17-4 1 20304 PIN
17-5 2 33786 FLAT WASHER
17-6 1 20723 BRACKET
17-7 1 20116 PIN
17-8 2 24724 RETAINING RING
18 -- -- OMIT
19 1 41238 BUSHING
20 -- -- OMIT
21 2 40147 GASKET
22 1 13050 BREATHER
23 1 40121 HYDRAULIC MOTOR
24 1 20712 CLUTCH
25 1 11637 OIL SEAL
26 2 41196 BUSHING
27 3 40510 THRUST WASHER
28 2 40518 KEY
29 1 41198 GEAR
30a 1 40598 WORM (HYDRAULICALLY DRIVEN)
30b 1 40635 WORM (MECHANICALLY DRIVEN)
31 -- -- OMIT
32 2 40396 RETAINING RING
33 2 40395 BEARING
34 2 32220 PLUG

15
RUFNEK 10 BIL
RUFNEK 10 BILRUFNEK 10 BIL
RUFNEK 10 BILL OF MATERIAL
L OF MATERIAL L OF MATERIAL
L OF MATERIAL CONTINUED
CONTINUEDCONTINUED
CONTINUED
35 1 32566 O-RING
36 -- -- OMIT
37 -- -- OMIT
38 2 40410 CAPSCREW
39 2 20270 CAPSCREW
40 2 20271 NUT
41 2 20526 LOCKWASHER
42 1 41244 C.T.O. HANDLE
43 1 41250 HANDLE GRIP
44 1 21128 GREASE ZERK
45 1 40069 BRAKE HOUSING
46 1 40617 BRAKE HUB
47 2 40075 FRICTION DISC
48 2 40076 STATOR PLATE
49 1 40113 CLUTCH CAM
50 1 40077 SPRING
51 1 40078 THRUST WASHER
52 1 40775 SET SCREW
53 1 40774 LOCKNUT
54 1 29044 WASHER
55 1 40599 BRAKE SPACER
56 2 40546 CAPSCREW
57 -- -- OMIT
58 1 40082 END CAP
59 1 20232 OIL SEAL
60 1 20105 KEY
61 1 20092 WASHER
62 1 20278 CAPSCREW
63 1 44024 RUFNEK PLATE

16
TOR UE SPECIFICATION
TOR UE SPECIFICATIONTOR UE SPECIFICATION
TOR UE SPECIFICATIONS CHART
S CHARTS CHART
S CHART
Dry Plated Lubricated Dry Plated Lubricated
SAE
Grade 5
SAE
Grade 5
SAE
Grade 5
SAE
Grade 8
SAE
Grade 8
SAE
Grade 8
Nominal Size
Torque
*(Ft-Lbs)
Torque
*(Ft-Lbs)
Torque
*(Ft-Lbs)
Torque
*(Ft-Lbs)
Torque
*(Ft-Lbs)
Torque
*(Ft-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%

17
CLUTCH INSPECTION
CLUTCH INSPECTIONCLUTCH INSPECTION
CLUTCH INSPECTION

18
RUFNEK
RUFNEK RUFNEK
RUFNEK 1
11
10 ISOMETRIC DRAWING
0 ISOMETRIC DRAWING0 ISOMETRIC DRAWING
0 ISOMETRIC DRAWING
TWG
PO Box 1130
Jenks OK 74037-1130 USA Phone: [phone]
www.dovertwg.com