Tulsa Rufnek Intelliguard 506W Operating instructions

Sel-0010(FOR PDF).doc
REV-1
Operating and
Maintenance Manual
Planetary Winch
This manual MUST be kept with the winch at all times. New
winch operators MUST read and understand the contents fully.
Sel-0010.doc
REV-1

FAILURE TO HEED THE FOLLOWING WARNINGS
MAY RESULT IN SERIOUS INJURY OR DEATH!
•Do not use to lift or move people. If your task involves
moving or lifting people, you must use the proper
equipment, not this winch.
•Winch operators must be trained in the proper, safe
operation of the winch.
•Cable anchors on Tulsa Winches are not designed to
hold the rated load of the winch. You must keep at least
five (5) wraps of cable on the drum to insure that the
cable doesn’t come loose.
•Stay clear of suspended loads and of cable under
tension. A broken cable or dropped load can cause
serious injury or death.
•Make sure that all equipment, including the winch and
cable, is maintained properly. Pay especially close
attention to the clutch, making sure that it fully engages
when shifted. Do not attempt to disengage the clutch
when a load is on the winch.
•Avoid shock loads. This type of load imposes a strain
on the winch many times the actual weight of the load
and can cause failure of the cable or of the winch.
WARNING

1
INTRODUCTION
Thank you for purchasing a new Tulsa Winch. We are proud of
our products and are certain that they will perform your winch
tasks properly. However, we do ask that you take a few minutes
to read and thoroughly understand this booklet. Also, if you have
new operators assigned to the winch, make sure that they read
and understand it. Because of the large number of models we
manufacture, we are unable to show parts lists for every model
in this booklet. If you want or need parts lists, please write Tulsa
Winch, 11135 S. James, Jenks, OK 74037. Or call (918) 298-
8300 or fax us at [phone]. You may also go to our Web
site at www.team-twg.com.
TABLE OF CONTENTS
General Operation 2
Theory Of Operation 3
Using A Snatch Block 3
Cable Considerations 4
The Importance Of A Proper Fleet Angle 5
Cable Installation 6
Winch Mounting 7
General Maintenance & Lubrication 8
Brake System 10
Model Codes 11
Warranty Inside Back

2
GENERAL OPERATION
1. Be sure to read all safety instructions thoroughly. It is
important that each operator is aware of the consequences
of misuse or poor operating practices of this winch.
2. Tulsa Winch products are not to be used to lift, hoist, or
move people. If your application requires moving persons,
you must use the proper equipment for the task.
3. Cable anchors on Tulsa Winch products are not designed to
hold the rated load of the winch. You must keep at least five
(5) wraps of cable on the drum to insure that the cable does
not come loose.
4. Personnel must stay clear of a suspended load or any line
under load. A distance of 1-1/2 times the length of the cable
should be maintained while the cable is under tension.
Failure to heed this warning may result in serious injury or
death.
5. Make sure that all equipment is maintained properly and
regular systems checks are performed to insure your winch
is working safely. Refer to the maintenance section of this
manual for details on these procedures.
6. Avoid shock loads. This type of load imposes a strain on the
winch many times the actual weight of the load and can
cause failure of the cable or of the winch.
7. Always inspect cable before beginning job. Never allow
cable to slide through hands while maintaining tension, use
hand-over-hand method to keep cable tension while
spooling. Always use leather gloves when handling cable.

3
THEORY OF OPERATION
1. The Tulsa Planetary Winches are composed of an input from
either a high torque, low speed geroler motor or a high-
speed gear or piston motor. Input drives through a multiple
disc brake that is spring applied and hydraulically released,
and then through planet gear sets to the cable drum.
2. During inhaul, the brake is not released since the load is
driven through a one-way cam clutch, bypassing the brake.
When the load comes to a stop, the cam clutch locks up and
the load is prevented from moving by the brake.
3. During payout, a brake valve is used to prevent the load
from moving faster than desired. This brake valve partially
blocks the main line from the motor back to the directional
control valve, allowing only a limited amount of oil through
the motor. Also, any time there is sufficient pressure to
modulate the brake valve, this same pressure releases the
multiple disc brake.
USING A SNATCH BLOCK
By using a snatch block you have effectively cut the load on the
winch in half. A snatch block should be used any time you have
a concern about the ability of the winch or cable to move a load.
The following illustration shows one way to rig such a block.

4
CABLE CONSIDERATIONS
As the number of layers of cable on a winch increases, the rated
capacity of the winch goes down. If you are operating at near the
top of the drum flanges, the effective rating of the winch is about
half of what it is on the first layer. You should therefore, only
keep as much cable on the winch as you need for your job.
Never use larger or smaller cable on your winch than is
recommended for it. The use of larger cable will not allow you to
pull larger loads and may, in fact, break easier than the proper
size cable. The use of smaller cable may overheat the winch due
to increased running time with more cable.
The following chart shows the recommended cable sizes for
Tulsa Winches
Winch Model Cable Size
506W 7/16”
707W 1/2”
1200W 9/16”
1500W 5/8”
3541RL 3/4”
RN45P 3/4”
RN60P 7/8”
RN80P 1”
RN100P 1”
RN130P 1 1/4”
Consult your local cable
supplier for recommendation
on the best type of cable and
hardware to use in your
specific application.
WARNING: CABLE ANCHORS
ON TULSA WINCHES ARE
NOT DESIGNED TO HOLD
THE RATED LOAD OF THE
WINCH. YOU MUST KEEP AT
LEAST 5 WRAPS OF CABLE
ON THE DRUM TO INSURE
THAT THE CABLE DOES NOT
COME.

5
Fleet Angle
THE IMPORTANCE OF A PROPER FLEET ANGLE
Maintaining the proper fleet angle is important to the success of
your winching operation, the life of your winch and the life of the
cable you are using. The fleet angle can best be described by
the following illustration.
The fleet angle should be kept as small as possible to insure
proper spooling and to maximize cable and winch life. To
promote even cable spooling, keep the fleet angle below three
degrees. Whenever possible, spool through a block at the back
of the truck body. Never pull directly against the flange of the
winch cable drum as this may cause the cable or the winch to
break.
If you are using a front mounted winch for vehicle recovery, use
a snatch block to avoid pulling sideways on the winch. If your
winch is equipped with a four way roller and you absolutely must
pull against a side roller, do so only for as long as is necessary
and carefully watch the cable on the drum. It will pile up on one
side of the drum and you must insure that it doesn’t jump over
the drum flange. When you are finished using the winch in a
manner where the cable does not spool evenly, disengage the
clutch and pay out the uneven cable. Then slowly re-spool the
cable, making sure that it lays evenly.

6
CABLE INSTALLATION
To install the cable wedge anchor, first consult the wire rope
manufacturer for recommendations on how to prepare the end of
the wire rope. Thread the prepared end of wire rope through the
smaller side of the opening of the cable drum wedge pocket. Pull
through enough cable to loop it back around and insert the end
back into the wedge pocket to about 3/4 depth. Install the wedge
in the loop then pull the slack out of the loop with the working
line. The wedge will slip into the pocket and secure the wire rope
into the drum.
To install the u-bolt clamp style of anchor, first prepare the end of
the cable as recommended by the wire rope manufacturer. Pass
the wire rope through the u-bolt so that the end extends
approximately 2x the diameter of the cable. Tighten the clamp
evenly until the wire rope begins to deform slightly under the u-
bolt and the cable is held securely.
WARNING: CABLE ANCHORS ON TULSA WINCHES ARE
NOT DESIGNED TO HOLD THE RATED LOAD OF THE
WINCH. YOU MUST KEEP AT LEAST 5 WRAPS OF CABLE
ON THE DRUM TO INSURE THAT THE CABLE DOESN’T
COME LOOSE.
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.

7
WINCH MOUNTING
You must make sure that your winch is securely mounted in
order for it to function properly and to insure safe operation. The
mount must be flat to insure proper alignment between the
gearbox side, the drum, and the clutch.
A rule of thumb to use when selecting capscrews to mount the
winch is to use the same size and number of capscrews to
fasten the winch to its mount as we use to fasten the gearbox
and end bracket to the winch frames. Winches must never be
fastened directly to the frame of a truck; mounting brackets as
shown below should be used.
All capscrews used to mount the winch should be Grade 8 or
better and should be carefully tightened to the proper torque
value for their size. All moving parts used to drive mechanical
winches should be secure and guards used, if they are in
accessible locations. If the winch being mounted is hydraulically
driven, make sure the system is clean and that all components
function properly, especially the relief valve.
Model No. of
Capscrews
Size
Capscrews
506W
707W
1200W
1500W
(USE MOUNTING HOLES PROVIDED IN BASE OF WINCH)
3541RL 10 3/4"
RN45P 8 7/8"
RN60P 8 7/8"
RN80P 8 7/8"
RN100P 8 1 1/8"
RN130P 8 1 1/8"

8
WINCH MAINTENANCE
A winch, like any other type of machinery, needs periodic
maintenance and inspection to maintain its performance
capabilities, give lasting value, and insure safe mechanical
workings. Good maintenance consists of three steps.
1. A daily inspection to insure that there are no oil leaks present,
that all mounting bolts and other fasteners are tight, and that
wire rope is in good condition.
2. Periodic servicing of the winch includes changing the oil in
both the gearbox and the brake section. Severity of use will
determine the need for oil changes but it should be checked at
a minimum of every 500 operating hours and changed every
1000 hours of operation. Factors such as extremely dirty
conditions or widely varying temperature changes may dictate
even more frequent servicing.
3. Complete teardowns and component inspections. Again,
severity and frequency of use will determine how often this
should be done. If the equipment on which this winch is
mounted is subject to inspection standards, then those
standards must also apply to the winch and be followed. If oil
changes reveal significant metallic particles, then a teardown
and inspection must be made to determine the source of
wear.
LUBRICATION
1. Check gearbox oil levels weekly. If the oil level does not show
a satisfactory amount, refill oil according to the individual
winch manual.
2. Check brake oil level and fill or replace if oil shows significant
metallic particles.
3. Lube all bushings equipped with grease zerks with a good
quality lithium based chassis lube.
4. Lubricate the cable based on your wire rope supplier’s
recommendations

9
Tulsa planetary winches are shipped from factory with SAE 90
EP gear lube in the gearbox and SAE 20-20W motor oil in the
brake section. This oil should be satisfactory for operation in
ambient temperatures from -10° F to +110° F. If your work calls
for operation in temperatures outside this range, contact Tulsa
Winch for recommendations.
The hydraulic system driving the winch should use only high
quality hydraulic oils from reputable suppliers. These oils should
contain additives to prevent foaming and oxidation in the system.
All winch hydraulic systems should be equipped with a return line
filter capable of filtering 10-micron particles from the system.
AIR SCHEMATIC
HYDRAULIC SCHEMATIC
A MOTOR SPOOL CONTROL VALVE
MUST BE USED WITH THE
INSTALLATION OF THESE PRODUCTS.
THE DRUM CLUTCH IS AIR OPERATED
AND REQUIRES COMPRESSED AIR
FOR ENGAGEMENT AND
DISENGAGEMENT OF THE CLUTCH

10
BRAKE SYSTEM
The winch braking system is a multiple disc, spring applied
hydraulically released setup that is activated via the port in the
brake housing. During pay-in the brake is not released but
bypassed through the one-way cam clutch. When the load
comes to a stop, the cam clutch locks up and the load is
prevented from slipping by the brake.
During payout, a brake valve is used to prevent the load from
moving faster that desired. This valve partially blocks the main
line from the motor back to the directional control valve, allowing
only a limited amount of oil through the motor.

11
WINCH MODEL CODES
(After 01-01-03)
RN100 P H L X O A 1
Basic Model
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 Seed Geroler
4. Two Speed Geroler
5. Piston
6. Vane
X. No Motor

12
WINCH MODEL CODES
(PRIOR TO 01-01-03)
RN100 L O 2 1
Basic Model
Gearbox Position
L=Left
R=Right
(viewed from rear of truck)
Cable Spooling
O=Over Drum
U=Under Drum
(viewed from rear of truck)
Motor Type
1=Single Speed Gear Motor
2=Two Speed Gear Motor
3=Single Speed Geroler Motor
5=Piston Motor
6=Vane
X=No Motor
Two speed gearbox
1=Without
2=With

13
ALL Tulsa Winches have the serial number, and assembly
number stamped on the housing or side plate. Please take a few
minutes to record these numbers for future use. The assembly
number will be required when ordering parts.
MODEL:
SERIAL NO:
ASSEMBLY NO:
TWG
PO Box 1130
Jenks OK 74037-1130 USA
Phone: [phone]
www.dovertwg.com

Tulsa Winch Limited Warranty Effective 8/1/2008
SUPERSEDES ALL PRIOR WARRANTIES
Sellerwarrants that each article(whetherGear DriveProducts, BrakeProducts and/or Winch Products, all of which arecoveredhereunder)soldunder
this order shall atthetimeof shipment(i) conform toapplicablespecifications, and (ii) befreefromdefects inmaterial and workmanshipduringnormal
and ordinary use and service (the "Warranty").
Buyer's exclusiveremedyandSeller's soleobligationunder this Warrantyshallbe, at Seller's option, torepairorreplaceanyarticleor partthereofwhich
has proventobedefective, or torefundthepurchasepriceof such articleor part thereof. Buyer acknowledges thatBuyer is knowledgeableconcerning
thearticles coveredbythis Warrantyandsoldin connectiontherewith whicharebeing purchased,that Buyerhas reviewedthis Warrantyandthatthe
remedies provided hereunder are adequate and acceptable to Buyer.
This Warrantyshall expire one (1) year from the date the article is first shipped bySeller. Noticeof claimed breach of thisWarrantymust begiven by
Buyer toSellerwithin theapplicableperiod. Such notice shallincludean explanationof theclaimedwarrantydefect and proof ofdateof purchaseof the
articleorpart thereof for which warrantycoverageis sought. No allowances shallbemadebySeller foranytransportation, laborcharges,parts,"inand
out" costs, adjustments or repairs, or anyother work, unless such items areauthorized in writing and in advance bySeller. Nor shall Seller have any
obligation to repair or replace items which by their nature are expendable.
If anarticleis claimedto bedefectivein material or workmanship,or nottoconformtotheapplicablespecifications, Seller willeitherexaminethearticle
at Buyer's site or issue shipping instructions for return to Seller. This Warranty shall not extend to any articles or parts thereof which have been
installed, used, or servicedotherwisethan in conformitywithSeller's applicablespecifications, manuals, bulletins, orinstructions, or which shallhave
been subjected to improper installation, operation, or usage, misapplication, neglect, incorrect installation, overloading, or employment for other than
normal and ordinary use and service. This Warrantyshall not applyto any articlewhich has beenrepaired, alteredordisassembled, or assembled by
personnel other than thoseof Seller. This Warrantyshallnot applytoanyarticleuponwhich repairs or alterations have been made(unless authorized
in writing and in advance bySeller). This Warrantyshall not applyto any articles or parts thereof furnished bySeller toBuyer's specifications and/or
furnished by Buyer or acquired from others at Buyer's request.
SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIESOFANYKIND, OTHERTHANTHEWARRANTYEXPRESSLY
SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALLOTHERWARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE.
Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to torsional vibration issues and is not
responsiblefor thedetection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed. Buyeracknowledges,
understands and agrees that this Warrantydoes not cover failures of theunit which result in any manner from the operation of the machine or unitat
vibrationfrequencies at or near the natural frequencyvibration of themachinein such awaythat damagemayresult. Buyer expresslyagrees thatSeller
is notresponsiblefor failuredamageoracceleratedwear caused bymachineorambient vibration. Further, BuyeracknowledgesandagreesthatBuyer
is always solely responsible for determination and final approval of the “application factor”which may be used in Seller’s calculations, and this
application factor is 1.0 unless otherwise stated in Seller’s quotation specifications.
The remedies for this Warranty shall beonly thoseexpressly set forth above, to theexclusion of any and all other remedies of whatsoever kind. The
limited remedies set forth above shall bedeemedexclusive,even though theymayfail their essentialpurpose. No agreement varyingorextending the
foregoing Warranty, remedies, exclusions, or limitations shall beeffectiveunless in a writing signed byan executiveofficer of Seller and Buyer. This
Warrantyis non-transferable. If apartywhohadpurchasedarticlesfromBuyer, or frompersons inprivitywith Buyer,brings anyaction or proceeding
against Seller for remedies other than those set forth in this Warranty, Buyer agrees to defend Seller against the claims asserted in such action or
proceedingatBuyer’s expense, includingthepayment of attorneys’fees andcosts, andindemnifySeller and hold Seller harmlessof, fromandagainst
all such claims, actions, proceedings or judgments therein. Buyer also agrees to defend and indemnify Seller of, from and against any loss, cost,
damage,claim, debt or expenses, including attorneys’fees, resulting fromanyclaims byBuyeror third parties topropertyor injurytopersons resulting
from faulty installation, repair or modification of the article and misuse or negligent operation or use of the article, whether or not such damage to
propertyorinjurytopersons maybecausedbydefective material,workmanship, or construction. ADVISORY: Winches andhoists arenot approved
for lifting or handling personnel or persons unless specifically approved in writing from Seller for the specific intended application.
Under no circumstances shall Seller be liable (i) for anydamage or loss toanyproperty other than thewarranted article or part thereof, or (ii) for any
special, indirect, incidental, or consequential damageor loss, even though such expenses, damages, or losses may be foreseeable.
The foregoing limitations on Seller's liabilityin theevent of breach of warranty shall also be theabsolutelimitof Seller's liability in theevent of Seller's
negligencein manufacture, installation, or otherwise, with regard tothearticles coveredbythis Warranty, and at theexpirationoftheWarrantyperiodas
above stated, all such liabilities shall terminate. Buyer’s purchase of any article(s) covered by this Warrantyshall constitute acceptanceof the terms
andconditions hereof and shall bebinding upon Buyer and Buyer’s representatives, heirs and assigns. Thelaws of theStateofOklahomashallgovern
Buyer’s rights and responsibilities in regard to this Warrantyand the transaction(s) subject thereto, and theState of Oklahomashallbetheexclusive
forum and jurisdiction for any action or proceedings brought by Buyer in connection herewith or any dispute hereunder. If any of the terms and
conditions contained within this Warranty are void, the remaining provisions thereof are and shall remain valid and enforceable.
Note: Prices and specifications contained in this price book are subject to change without notice.