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Tulsa RUFNEK 20, Service Manual

The Tulsa RUFNEK 20 Service Manual is a must-have companion for owners of this cutting-edge product. This comprehensive manual provides step-by-step instructions, troubleshooting guides, and valuable tips to ensure seamless operation. Download it for free at manualshive.com, and explore the full potential of your Tulsa RUFNEK 20!

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SEL-0045-001.DOC 
REV-0 

 July 2020

RUFNEK 20 

AND 

MODEL 23 

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 ADJUSTMENT ...........................................................................................................................................................8 

DISASSEMBLY ............................................................................................................................................ 9 

RUFNEK 20 BRAKE DISASSEMBLY......................................................................................................................................9
MODEL 23 BRAKE DISASSEMBLY........................................................................................................................................10
CLUTCH AND DRUM DISASSEMBLY....................................................................................................................................11
GEARBOX DISASSEMBLY.....................................................................................................................................................12
GEAR INSPECTION INSTRUCTIONS ....................................................................................................................................13 

ASSEMBLY ................................................................................................................................................ 14 

GEARBOX ASSEMBLY ..........................................................................................................................................................14
MODEL 23 BRAKE ASSEMBLY..............................................................................................................................................15
RUFNEK 20 BRAKE ASSEMBLY............................................................................................................................................15
CLUTCH AND DRUM ASSEMBLY..........................................................................................................................................16 

TROUBLESHOOTING................................................................................................................................ 16

 

BILL OF MATERIAL................................................................................................................................... 16

 

TORQUE SPECIFICATIONS CHART ........................................................................................................ 16

 

CLUTCH INSPECTION .............................................................................................................................. 16

 

ISOMETRIC DRAWING.............................................................................................................................. 16

 

RUFNEK BRAKE, HYDRAULIC MOTOR, & CLUTCH POSITION INDICATOR...................................... 16

 

DESIGN SERIES 001 

Summary of Contents for RUFNEK 20

Page 1: ... 9 RUFNEK 20 BRAKE DISASSEMBLY 9 MODEL 23 BRAKE DISASSEMBLY 10 CLUTCH AND DRUM DISASSEMBLY 11 GEARBOX DISASSEMBLY 12 GEAR INSPECTION INSTRUCTIONS 13 ASSEMBLY 14 GEARBOX ASSEMBLY 14 MODEL 23 BRAKE ASSEMBLY 15 RUFNEK 20 BRAKE ASSEMBLY 15 CLUTCH AND DRUM ASSEMBLY 16 TROUBLESHOOTING 16 BILL OF MATERIAL 16 TORQUE SPECIFICATIONS CHART 16 CLUTCH INSPECTION 16 ISOMETRIC DRAWING 16 RUFNEK BRAKE HYDRAULIC M...

Page 2: ...ved by a qualified person All welding should also be done by a qualified person Winch mount must be flat so as not to induce binding The flatness must not exceed 1 16 inch across the mounting surface of the winch itself Guards must be placed on all open drives in the case of mechanical winches Insure that all hydraulic hoses valves and fittings are rated to winch manufacturer s operating pressures...

Page 3: ...tch is fully engaged before hoisting A visual inspection of the drum clutch engagement is required before each winching operation Must rig all loads secure before winching Pull the load line taut and inspect the condition of load for stability Must inspect the drum brake if equipped The drum brake is not a load holding device it is design to prevent over spooling of the drum and causing bird nesti...

Page 4: ...eries designation number will be issued for the winch A new manual will also be created for that specific design series WINCH BREAK WINCH BREAK WINCH BREAK WINCH BREAK IN IN IN IN Winches like any other kind of machinery require a break in to perform well and to maximize their life The following guidelines should be used in the break in of Tulsa Winches Use extreme care when first spooling cable o...

Page 5: ...o Speed Gear Motor 3 Single Speed Geroler Motor 4 Two Speed Geroler Motor 5 Piston 6 Vane X No Motor RN20 W M R F O M X Winch Type M Mechanical H Hydraulic No of Worm Starts S Single D Double Worm Angle L Left R Right Input Shaft Location F Front R Rear X Does not apply viewed from rear of truck Cable Spooling O Over Drum U Under Drum viewed from rear of truck Motor Mount D Direct Mount X No Motor...

Page 6: ...f normal usage Tulsa Winch recommends that the oil level in the gearbox be checked and adjusted as part of the pre use inspection If the oil level drops frequently or oil leakage is detected during an inspection maintenance should be performed to correct any problems GEARBOX OIL CAPACITY 3 QTS Gearbox oil level inspection is achieved by removing the oil level inspection plug and visually inspectin...

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

Page 8: ...rews rotate the cam 60 degrees in the loosening direction and reinstall the capscrews in the new set of holes which have just been revealed After adjustment be sure to re tighten the cam capscrews securely If the input to the winch is accessible and a torque wrench can be put on it the brake can be set with a torque wrench The Model 23 brake is shipped from the factory pre set at 50 Ft Lbs ADJUSTA...

Page 9: ... the capscrews 14 from the brake cover 97 4 Remove the spring 101 Remove the brake driver 100 along with the brake components 91 98 103 104 and 105 5 Inspect parts as follows replace if necessary A Inspect the friction discs 104 for uneven or excessive wear Friction discs should measure no less than 055 in thick B Inspect the the stator plates 103 for warpage or excessive wear C Inspect the spring...

Page 10: ...oles in the brake drum 8 and a gear puller to remove the brake drum 7 Inspect parts as follows replace if necessary A Inspect the brake shoes 5 for wear If the shoe linings are worn flush with the rivet heads they must be replaced B Inspect the brake drum 8 for severe wear or scoring C Check the inside lower part of the brake housing 18 for the presence of oil Replace the seal 10 if oil is present...

Page 11: ...the keys 50 and thrust washers 54 from the output shaft 49 7 Remove the brake band assembly by loosening the nuts on the rod 67 to remove tension on the spring 70 Then remove the cotter key 65 pin 63 attaching clevis 64 to control arm 60 Finally remove the capscrews 66 washers 27 and nut 28 attaching the brake band to the frame 8 Slide the drum 52 off the output shaft 49 using an overhead hoist 9 ...

Page 12: ... Remove the carrier 43 by removing the roll pin 46 Finally remove the keys 45 4 Remove the worm 37 from the housing 36 by removing either the motor 81 and motor adapter 85 or just the end cap 39 depending on the type of drive From the brake end push the worm 37 out of the housing 36 If the brake has not been removed see brake disassembly on page 9 or 10 5 Inspect parts as follows replace if necess...

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

Page 14: ... Press a new oil seal 10 into the end cap 39 Attach the end cap 39 to the housing 36 with six capscrews 17 using the gasket 19 3 Install the keys 45 into the output shaft 49 4 Bolt the gear 35 to the carrier 43 using eighteen capscrews 44 nuts 12 and washers 13 5 Install the assembled gear onto the shaft 49 Press the roll pin 46 into the carrier 43 Slide the bushings 21 on to both ends of the outp...

Page 15: ... RUFNEK RUFNEK 20 20 20 20 BRAKE BRAKE BRAKE BRAKE ASSEMBLY ASSEMBLY ASSEMBLY ASSEMBLY 1 Press the oil seal 108 into the brake housing 88 Install the gasket 19 and attach the brake housing to the gearbox with six capscrews 93 2 Install the key 90 and coupler 106 onto the worm Next install the clutch driver assembly Items 91 98 100 and 105 onto the coupler 106 3 With the retaining ring 105 on the c...

Page 16: ...utch 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 deact...

Page 17: ...place 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 gearbox a Damaged motor shaft se...

Page 18: ...WASHER 16 4 28578 CAPSCREW 17 12 20289 CAPSCREW 18 1 23874 BRAKE HOUSING 19 2 20117 GASKET 20 2 20517 PIN 21 2 20754 BUSHING 22 1 20771 LEFT FRAME 23 1 20772 RIGHT FRAME 24 3 20286 PLUG 25 8 20295 NUT 26 8 20558 WASHER 27 13 20526 WASHER 28 13 20271 NUT 29 8 20406 CAPSCREW 30 5 21128 GREASE ZERK 31 4 20268 CAPSCREW 32 7 20325 CAPSCREW 33 1 40771 COVER M23 33a 1 44028 COVER RUFNEK 34 2 20181 GASKET...

Page 19: ...46 1 20717 PIN 47 5 20521 NUT 48 2 20756 BUSHING 49 1 25491 SHAFT 50 2 20101 KEY 51 1 21154 U BOLT 52 1 20991 DRUM 53 1 20993 CLUTCH 54 2 20774 WASHER 55 1 21058 CLUTCH 56 1 20129 BRACKET 57 1 20330 END BRACKET 58 1 20757 BUSHING 59 4 20276 CAPSCREW 60 1 20074 CONTROL ARM 61 2 20108 SHAFT 62 2 20000 CONTROL ARM 63 1 939243 PIN 64 1 20054 CLEVIS 65 1 20514 COTTER PIN 66 2 20270 CAPSCREW 67 1 20112 ...

Page 20: ...1000 WASHER 87 1 41272 OIL SEAL 88 1 43962 BRAKE HOUSING 89 1 12208 BUSHING 90 1 25519 KEY 91 1 33565 CAM CLUTCH 92 1 43960 SPRING PLATE 93 6 24475 CAPSCREW 94 OMIT 95 1 41406 ADJUSTING NUT 96 1 41411 O RING 97 1 43958 BRAKE COVER 98 1 29084 RETAINING RING 99 2 21684 PLUG 100 1 44149 BRAKE DRIVER 101 1 33559 SPRING 102 1 17344 O RING 103 9 44141 STATOR PLATE 104 5 33564 FRICTION DISC 105 1 44145 R...

Page 21: ...0 53 42 7 16 20 55 41 33 78 58 47 1 2 13 76 57 45 106 80 64 1 2 20 85 64 51 120 90 72 9 16 12 109 82 65 153 115 92 9 16 18 122 91 73 172 129 103 5 8 11 150 113 90 212 159 127 5 8 18 170 128 102 240 180 144 3 4 10 266 200 160 376 282 226 3 4 16 297 223 178 420 315 252 7 8 9 430 322 258 606 454 364 7 8 14 474 355 284 668 501 401 1 8 644 483 386 909 682 545 1 14 721 541 433 1019 764 611 1 1 8 7 794 5...

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

Page 23: ...23 ISOMETRIC DRAWING ISOMETRIC DRAWING ISOMETRIC DRAWING ISOMETRIC DRAWING FOR RUFNEK BRAKE HYDRAULIC MOTOR AND YOKE WITH CLUTCH POSITION INDICATOR SEE PAGE 24 ...

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

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