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