Tulsa Rufnek 100 User manual

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

4
GENERAL INFORMATION
GENERAL INFORMATIONGENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION AND THEORY OF OPERATION
INTRODUCTION AND THEORY OF OPERATIONINTRODUCTION AND THEORY OF OPERATION
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
ASSEMBLY NUMBER EXPLANATIONASSEMBLY NUMBER EXPLANATION
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.
WINCH BREAK
WINCH BREAKWINCH BREAK
WINCH BREAK-
--
-IN
ININ
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.
81370 001
ASSEMBLY # SERIES
DESIGN

5
MODEL CODES
MODEL CODESMODEL CODES
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
RN100 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
Motor Type
CL-CharLynn
M80 S L R F O D CL
G=Speed Reducer
T=Triple
Gearbox Location
L=Left
R=Right
(viewed from rear of truck)
THE RUFNEK SERIES
WINCHES ARE ONLY
AVAILABLE WITH LEFT
HAND GEARS.

6
MAINTENANCE
MAINTENANCEMAINTENANCE
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.
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.
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
MOBIL SHC 626
MOBILUBE HD80W140
SAE 140W AGMA 7 EP

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

8
BR
BRBR
BRAKE IDENTIFICATION
AKE IDENTIFICATIONAKE IDENTIFICATION
AKE IDENTIFICATION AND ADJUSTMENT
AND ADJUSTMENT AND ADJUSTMENT
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.

9
BRAKE IDENTIFICATION AND ADJUSTMENT
BRAKE IDENTIFICATION AND ADJUSTMENT BRAKE IDENTIFICATION AND ADJUSTMENT
BRAKE IDENTIFICATION AND ADJUSTMENT CONTINUED
CONTINUEDCONTINUED
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.

10
DISASSEMBLY
DISASSEMBLYDISASSEMBLY
DISASSEMBLY
DRUM
DRUM DRUM
DRUM BRAKE DISASSEMBLY
BRAKE DISASSEMBLYBRAKE DISASSEMBLY
BRAKE DISASSEMBLY
1. Loosen the capscrews (31).
2. Remove the capscrews (88) from the
cover (86).
3. Remove the cover (86) from the
gearbox.
4. Remove the brake shoes (98).
5. Remove the nut (97) and washer
(96).
6. Use the two threaded holes in the
brake drum (95) and a gear puller to
remove the brake drum.
7. Inspect parts as follows, replace if
necessary:
A. Inspect the brake shoes (98) for
wear. If the shoe linings are worn
flush with the rivet heads, the
shoes must be replaced.
B. Inspect the brake drum (95) for
severe wear or scoring.
C. Check the inside lower part of the
gearbox housing for the presence
of oil. Replace the seal (37) if oil
is present
If replacing the seal (37), first
drain the oil from the gearbox then
remove the capscrews (94) and
brake cover (93).

11
ADJUSTABLE OIL BRAKE DISASSEMBLY
ADJUSTABLE OIL BRAKE DISASSEMBLYADJUSTABLE OIL BRAKE DISASSEMBLY
ADJUSTABLE OIL BRAKE DISASSEMBLY
1. Drain the oil from the brake by
removing the drain plug (21).
2. Loosen the spring tension inside the
brake by turning the adjusting
mechanism (22) clockwise until it
stops.
Extreme care should be taken
when removing the cover of the
brake housing. The cover
compresses the spring which is
used to set the brake, thus the
cover is spring loaded against the
cover screws.
3. Loosen and remove the capscrews
(13) and washers (14) from the brake
cover (20). If needed, rotate the
adjusting mechanism counter-
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.
5. Remove the spring (10). Grasp the
brake driver (8) and remove the
brake components.
6. Inspect stator plates (16), friction
discs (17), and retaining ring (7) for
wear and replace them if necessary.
7. Noting the direction that the cam
clutch (6) is installed, inspect it for
wear. Replace if necessary.
Failure to re-install the clutch in
the correct orientation will result
in the brake engaging in the
opposite direction.
8. If necessary, remove the reaction
housing (2) and replace the oil seal
(19).
FOR CORRECT PART
SEQUENCE NUMBERS
REFER TO PAGE 27 FOR
ADJUSTABLE BRAKE
BILL OF MATERIAL

12
NON
NONNON
NON-
--
-ADJUSTABLE BRAKE DISASSEMBLY
ADJUSTABLE BRAKE DISASSEMBLYADJUSTABLE BRAKE DISASSEMBLY
ADJUSTABLE BRAKE DISASSEMBLY
1. Place a container underneath the
brake to catch the oil when the cover
is removed.
Extreme care should be taken
when removing the cover of the
brake housing. The cover
compresses the spring which is
used to set the brake, thus the
cover is spring loaded against the
cover screws.
2. Evenly loosen and remove the
capscrews (20) and washers (21)
from the brake cover (17) to dislodge
the cover.
3. Remove the spring (14), then grasp
the brake driver (9) and remove the
brake components.
4. Inspect the stator plates (12), friction
discs (13), and retaining ring (11) for
wear and replace them if necessary.
5. Noting the direction that the cam
clutch (8) is installed, inspect it for
wear. Replace if necessary.
Failure to re-install the clutch in
the correct orientation will result
in the brake engaging in the
opposite direction.
If necessary, remove the reaction
housing (3) and replace the oil seal
(16).
FOR CORRECT PART
SEQUENCE NUMBERS
REFER TO PAGE 28 FOR
NON-ADJUSTABLE BRAKE
BILL OF MATERIAL

13
RUFNEK
RUFNEKRUFNEK
RUFNEK ADJUS
ADJUS ADJUS
ADJUSTABLE OIL
TABLE OILTABLE OIL
TABLE OIL BRAKE DISASSEMBLY
BRAKE DISASSEMBLY BRAKE DISASSEMBLY
BRAKE DISASSEMBLY
1. Remove the bottom drain plug (9) to
drain oil from brake.
2. Loosen the spring tension inside the
brake by rotating the adjusting
mechanism (6) clockwise until it
stops.
Extreme care should be taken
when removing the brake cover.
the cover is spring loaded against
the cover screws.
3. Evenly remove the capscrews (11)
and washers (12) from the brake
cover (7).
4. Remove the spring (13) and retaining
ring (21), then remove the brake
driver (23) along with the brake
components (19, 20, 21, 22, 23, 25,
26, 27, and 28 ).
5. Inspect parts as follows, replace if
necessary:
A. Inspect the friction discs (19) for
uneven or excessive wear.
Friction discs should measure no
less than .055-in thick.
B. Inspect the stator plates (20) for
warpage or excessive wear.
C. Inspect the spring (13) for
damage or discoloration.
D. Cam clutch (25) should be free of
debris and have all cams intact.
If replacing the cam clutch (25),
take note of the direction it
locks up for reassembly.
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

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

15
GEAR
GEARGEAR
GEARBOX
BOXBOX
BOX DISASSEMBLY
DISASSEMBLY DISASSEMBLY
DISASSEMBLY
1. Supporting the end of the output
shaft (78) with a hoist, remove the
housing cover (80) by removing
capscrews (1 & 43), nuts (17 & 34),
and washers (16 & 35).
2. Use the hoist to lift the output shaft
(78), bushings (77), keys (76), and
gear (assembled items 24, 25, 71,
72, 73, 74, and 75) out of the
housing (61).
3. Remove the bushing (77) from the
output shaft (78).
4. Remove the gear (71) from the
carriers (74) by removing the sixteen
capscrews (75), nuts (24), and
washers (25), then pull the carrier
(74) off of the shaft (78). Finally,
remove the spacer (73), carrier (74),
and keys (76).
5. Remove the worm assembly
(assembled items 58, 59, 60, and 91)
from the housing by removing either
the motor (99) and motor adapter
(93) or the end cap (59), depending
on type of drive. From the brake
end, push the worm assembly out of
the housing (90).
6. Disassemble the worm by removing
the nut (54) and washer (55) then
sliding off the bearing retainer (59),
along with the two sets of angular
bearings (58). Finally, remove the
third set of bearings (91).
If the brake has not been removed,
see brake disassembly on pages
10-13 of this manual.
7. Inspect parts as follows, replacing
them if necessary:
A. Inspect the inner carriers (74) for
damage.
B. Inspect the gear (71) for
excessive wear or damage. See
page 16 for detailed instructions.
C. Inspect the keys (76) and
bushings (77) for damage.
D. Inspect the worm (60) for
excessive wear or signs of heat
checking or cracks.
E. Inspect the bearings (58 & 91)
and seals (37 & 58) for excessive
wear or damage.

16
GEAR INSPECTION INSTRUCTIONS
GEAR INSPECTION INSTRUCTIONSGEAR INSPECTION INSTRUCTIONS
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

17
ASSEMBLY
ASSEMBLYASSEMBLY
ASSEMBLY
GEAR
GEARGEAR
GEARBOX
BOXBOX
BOX ASSEMBLY
ASSEMBLY ASSEMBLY
ASSEMBLY
1. Press the angular bearings (58) into
the bearing retainer (59), then slide
the bearing retainer and bearings
onto the worm (60) and secure with
nut (54) and washer (55).
When installing the two angular
bearings, it is imperative that they
are installed with the surface text
facing the outside of the housing.
2. For winches driven by a hydraulic
motor:
Install the motor adapter (103) and
worm assembly with eight capscrews
(104), using gasket (68). Attach the
motor (99) with four capscrews
(101), using gasket (102).
For winches driven by a PTO
sprocket and chain:
Press a new oil seal (48) into the end
cap (50). Install the worm assembly
into the gearbox (90), using gasket
(68). Secure the end cap (50) with
eight capscrews (53), using gasket
(51). Install the key (65) into the
worm (60) shaft.
3. Install the keys (76) into the output
shaft (78).
4. Slide the carrier (74) over the keys
(76). Install the spacer (73) using
two pins (72). Slide the gear (71)
and the other carrier (74) onto the
shaft and secure with sixteen
capscrews (75), nuts (24), and
washers (25).
5. Install the assembled gear onto the
shaft (78). Slide the bushings (77)
onto both ends of the shaft.
6. Install the output shaft assembly into
the housing (90).
7. Install both gaskets (81) onto the
housing (90). Attach the cover (80)
to the housing, using capscrews
(1 & 43), nuts (17 & 34), washers
(16 & 35), using gaskets (81).

18
DRUM
DRUMDRUM
DRUM BRAKE ASSEMBLY
BRAKE ASSEMBLYBRAKE ASSEMBLY
BRAKE ASSEMBLY
1. Press the oil seal (37) into the end
cap (93). Install the gasket (92), and
attach the end cap (93) to the
gearbox with six capscrews (94),
using gasket (92).
2. Install the brake drum (95) and key
(89) onto the worm shaft (60).
Secure the brake drum with the nut
(97) using washer (96). Bend two
tabs of the washer (96) over the flats
of the nut (97).
3. If removed, reattach the cam (85) to
the brake cover (86) using two
capscrews (31) and washers (87).
4. Install the brake cover (86), cam
(85), and brake shoes (98) into the
gearbox.
5. Secure the brake cover (86) using
eight capscrews (88).
6. Adjust the brake using the procedure
on page 8 of this manual.

19
ADJUSTABLE
ADJUSTABLE ADJUSTABLE
ADJUSTABLE OIL
OIL OIL
OIL BRAKE AS
BRAKE ASBRAKE AS
BRAKE ASSEMBLY
SEMBLYSEMBLY
SEMBLY
1. Press the oil seal (19) into the
reaction housing (2), then mount the
reaction housing to the gearbox with
six capscrews (12), using a gasket
(18).
2. Install the key (1), coupler (5), and
clutch/driver assembly (3, 6, 7, 8),
onto the worm shaft (57).
3. Install the retaining ring (11) into the
reaction housing (2), then install the
stator plates (16) and friction discs
(17) in the correct stack up, as
shown below.
4. Install the spring (10) and then press
the adjusting mechansim assembly
(items 9, 22, 23) into the brake cover
(20).
5. Attach the brake cover (20) with
eight capscrews (13) and washers
(14), using a gasket (15).
6. Fill the gearbox and brake with the
proper oil. Refer to the winch
maintenance section of this manual
for oil type and amounts.
FOR CORRECT PART
SEQUENCE NUMBERS
REFER TO PAGE 27 FOR
ADJUSTABLE BRAKE
BILL OF MATERIAL

20
NON
NONNON
NON-
--
-ADJUSTABLE
ADJUSTABLEADJUSTABLE
ADJUSTABLE OIL
OIL OIL
OIL BRAKE ASSEMBLY
BRAKE ASSEMBLYBRAKE ASSEMBLY
BRAKE ASSEMBLY
1. Press the oil seal into the reaction
housing (3), then mount the reaction
housing to the gearbox with six
capscrews (5), using a gasket (2).
2. Install the key (4), coupler (6), and
clutch/driver assembly (7, 8, 9, and
10), onto worm shaft (60).
3. Install the retaining ring (11) into the
reaction housing (3), then install the
stator plates (12) and friction discs
(13) in the correct stack up, as
shown below.
4. Install the spring (14) then press the
washer (16) into the brake cover
(17).
5. Secure the brake cover (17) with
eight capscrews (20) and washers
(21), using a gasket (15).
6. Fill gearbox and brake with proper
oil. Refer to winch maintenance
section of this manual for oil type and
amounts.
FOR CORRECT PART
SEQUENCE NUMBERS
REFER TO PAGE 27 FOR
NON-ADJUSTABLE BRAKE
BILL OF MATERIAL