Service Manual Model 506W Winch
Contents
1. 0 EE A 8 SERVICING THE 2 2 9 SERVICING THE 2 22 10 SERVICING THE PLANETARY 1 12 5 13 BILL 85 14 EXPLODED ISOMETRIC ASSEMBLY 1 1 2 16 G SERVICE LITERATURE S06W SERVICE LIT SEL 0014 doc 1 MODEL CODE 5 06 LOA DCL Basic Model q aac Char Lynn Motor 6 1 Ratio Size Drum Winch Spool Over Drum Left Right Mount PART amp SERIAL NUMBER LOCATION Part and serial numbers can be located on the winches as shown below YEAR LOG SAFETY NOTES A WARNING FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJ URY OR DEATH Tulsa winches are not to be used to lift hoist or move people If your task involves lifting or moving people you MUST use2. place a magnetic base dial indicator on the planet carrier and adjust the plunger of the dial indicator at the approximate middle of one of the planet gear teeth Using a screwdriver or your finger rotate the planet gear back and forth reading the movement on the dial indicator If the total movement is greater than 0 025 then the drum should be replaced Carefully turn winch over so motor side is down Remove five capscrews 39 holding side plate tem 2 Remove two capscrews 43 from support rod ends Remove five capscrews tem 42 holding output shaft tem 6 Remove side plate Slide output shaft 6 out of drum 3 Inspect retaining ring 7 to insure it is still in groove and is not bent over replace if necessary Inspect bearing tem 5 for signs of spalling or pitting and if necessary replace the bearing 5 and seal 4 located in the drum REASSEMBLY Thoroughly clean all parts Replace those which show wear or damage Inspect the drum tem 3 and base tem 15 for structural integrity and replace if necessary Install bearing tem 5 and seal tem 4 into drum Slide drum onto shaft tem 6 aligning and seating bearing to shaft Install snap ring tem 7 onto shaft tem 6 Attach side plate tem 7 to shaft 6 using six capscrews 42 making sure the vent is oriented properly Then using five capscrews tem 39 attach side plate
3. 42353 BRAKE COVER 2B A 42514 BRAKE COVER 2B A 42636 BRAKE COVER 2B A 43604 BRAKE COVER 2B A 43608 1 BRAKE COVER 2 42358 BRAKE PISTON 42359 BRAKE DRIVER 42637 BRAKE DRIVER 42347 BASE 42378 1 INPUTSUN GEAR 43510 1 INPUT SUN GEAR 42529 1 MOTOR 2 BOLT A 11 9 In 42386 COUNTER BALANC E VALVE 42384 2 SUPPORTROD 42396 STUD 41740 BRAKE DRIVER 41723 RACE 26980 2 RETAINING RING 41743 2 BUSHING 29043 1 RETAINING RING 41759 CLUTCH 41994 1 RETAINING RING 14 ul ul gt NINININININ e e ae 3 Js 38 21 a 11 12 el B O 20 1 2 28 A 2 m 28 1316 1 ORING 9 437 1 BACKUPRING a 20 ORe 40336 1 BACKUPRING 418 12 BRAKESPRING 41873 1 SWNELADAPTER 465 11 4092 2 1 09 1 22237 47 1 ORING PLUG SS 20 00 865 1 CAPSCREW CAPSC REW 5 346 2 CAPSCREWSOCKETHEAD 4 40 2 55 956 1 O a o 1 NIN m 15 EXPLODED ISOMETRIC ASSEMBLY DRAWING
4. Remove the four capscrews 47 and the counterbalance block 18 from the motor 17 Remove the counterbalance valve from the counterbalance block and inspect the small metering hole located on the side of the cartridge valve to make sure it is not obstructed See Fig 5 Also inspect the Orings 50 to insure that they not cut or flattened Replace if necessary Motors and cartridge valves are not serviceable in the field Return them to an authorized dealer for service METERING HOLE Fig 5 SERVICING THE BRAKE Evenly remove the one capscrew 41 and five nuts 40 holding the brake cover in place Spring pressure will raise the cover up as the capscrew and nuts are loosened Remove the cover from the brake housing Remove the springs tem 32 from the piston tem 13 and check them for free height Each spring should measure at least 1 200 inches with no force on them Remove the brake piston 13 by installing two pieces of 3 8 16NC all thread in the bottom of two spring pockets Using jam nuts screw the all thread pieces in evenly until the piston is clear of the housing An alternate way of removing the piston is to use a portable power unit or air to slowly pressurize the brake cavity and blow the piston out of the bore Grasp the brake driver clutch assembly tem 14 and remove it from the brake housing Remove the stator plates tem 48 and friction discs tem 49
5. dimensions are within the tolerance shown on See Fig 7 drawing If your measurement is greater than shown either some friction discs and stator plates have been left out or the friction discs are worn beyond acceptable tolerances If your measurement is less than shown too many plates or discs have been inserted or they are not seated properly Install o ring 28 and back up ring 29 onto piston making sure back up ring is closest to outer edge See Fig 7 Next install o ring tem 30 and back up ring 37 onto piston making sure back up ring is closest to outer edge See Fig 7 10 14 Lubricate seals and back up ring then install the piston into the brake housing tapping it gently down until it is seated 15 Install the springs tem 32 into the spring pockets of the piston If working in a horizontal position coat the bottom of each spring with chassis lube to keep it in position 16 lubricate the new o ring Item 10 with light oil and install it into the groove on the brake cover 17 Install the cover onto the brake housing tem 77 and draw it down evenly alternating between opposite 41 and nuts 40 Make sure that the cover is aligned properly with the brake housing to orient the motor and oil ports as they should be 18 Check the brake release with a portable hydraulic pump Full release should be obtained at 340 psi plus or minus 20 psi Also che
6. from the brake housing and check them for excessive wear Replace if necessary Be sure to check the top stator plate for scoring caused by the removal tools and polish if necessary Friction discs should measure no less than 0 055 in thickness and stator plates should measure no less than 0 068 in thickness With a hook wire or pry bar remove the seal tem 34 Remove brake housing Item 11 from winch examine the journal on the brake housing where the seal tem 4 runs for wear If severely worn replace the brake housing Carefully dis assemble the brake driver clutch assembly noting the direction of lockup for the clutch Item 26 The clutch assembly must be re assembled with the arrow pointing in the proper direction for the winch to function properly Inspect the surface on the brake driver 14 where the clutch 26 runs If there is any pitting or spalling on the driver then it and the clutch must be replaced Re assemble the driver clutch assembly making sure that the clutch 15 installed properly Install a new seal tem 34 into the brake housing and reinstall brake housing into winch Install the stator plates 48 and friction discs 49 into the brake housing starting with a stator and alternating friction discs and stator plates There is one more stator plate than friction disc so you will finish with a stator plate After installation check the brake stack up to make sure that the
7. Gus Tulsa Winch Service Manual Model 506W Winch Table of Contents AALO D DDE OD DI DA EA E E E E AA 2 PART amp SERIAL NUMBER LOCATION cssssssssssssssssssssssssssssssssessssssssssssssssssesnssssssesesssessssssssesssessssssesesssessnsesossssesnseses 2 SAFETY 1 2 INTRODUCTION AND THEORY OF 2 21 3 HYDRAULIC 1 4 12 VE Se Ssa 5 WIRE 21 E 5 1 6 5 2 7 8
8. ck the brake for proper operation by applying 280 psi to the brake port and adapting a torque wrench to the input shaft The torque here in the payout direction should be 95 to 115 ft Ib 0 052 FY aS hy 5 11 SERVICING THE PLANETARY SET Remove the spiral rings from the planet pins Remove the pins from the carrier by carefully tapping them out Remove the planet gears thrust washers and bearings from the carriers Inspect the pins bearings and gear bores for evidence of wear and replace if necessary Before reassembly be sure to insert the round plates into the carriers To re assemble be careful to line up the planet pins with the thrust washers and bearings and then press the knurled part of the pin into the carrier If the pins are not lined up properly the thrust washers can be shattered during the pressing operation 12 TROUBLESHOOTING Problem Winch won t hold load Solution 1 Excessive back pressure in the system Check the system for restrictions and reduce the backpressure Solution 2 Brake discs are worn out Replace brake discs Solution 3 Winch clutch is slipping Inspect the clutch and driver for wear and replace worn parts Problem The winch will not raise the load it should Solution 1 Relief valve setting may be too low to allow proper lifting Increase relief valve pr
9. essure setting Solution 2 Load being lifted may be more than the winch s rating Reduce the load or re rig to increase mechanical advantage Problem The winch will not lower the load Solution 1 The brake valve was improperly hooked up after being disconnected Check plumbing and connect lines properly Solution 2 The cartridge in the brake valve may have a plugged metering hole Remove the cartridge and clean it if necessary Problem Oil leaks from the vent on the motor side of the winch Solution 1 The motor shaft seal may have failed Replace this seal and reduce backpressure if that caused the shaft seal to fail Solution 2 Brake piston seals may have failed Service the brake section and replace worn parts 13 BILL OF MATERIALS NO TWIPARTNO QTY DESCRIPTION y CONTACTFACTORY 1 SIDEPLATE CONTACTFACTORY 1 SIDEPLATE 42351 1 DRUM 7 1 2 barrel 11 1 8 flange 42834 1 DRUM 7 1 2 barel 11 7 8 flange 42837 1 DRUM 7 1 2 barrel 12 3 4 flange 43142 1 DRUM 7 1 2 barel 12 flange 42381 OIL SEAL 42386 2 BEARING 42356 SHAFT 996456 1 RETAINING RING 4178 1 PLANETARY GEAR SET 42377 OUTPUT CARRIER 30484 NEEDLE BEARING 42380 PLANET GEAR 28771 RACE 41715 RETAINING RING 42184 PLANET PIN 42383 PLATE 42379 BEARING CARRIER 33094 O RING 42355 BRAKE HO USING 43168 BRAKE HO USING 43509 BRAKE HO USING 43512 BRAKE HO USING
10. king up causing a load to fall and resulting in property damage personal injury or death 1 PIPE Fig 1 Fig 2 Fig 3 Fig 4 DISASSEMBLY Drain brake and gear oil See lubrication Section for instructions Stand the winch on its end with the motor pointing up Remove the brake line from the brake housing 17 Remove the motor and brake valve assembly from the winch by removing two capscrews 53 holding the motor to brake cover See Servicing The Motor section for motor and counterbalance valve dis assembly Remove the brake sub assembly from the winch by removing one capscrew 41 and five nuts tem 40 holding the brake housing to the side plate tem 2 Spring pressure will raise the cover as the nuts are loosened See Servicing The Brake section for brake repair Using two crows foot pry bars hook the bearing carrier Item 9 from inside and pull it out of the cable drum If necessary remove and replace the bearing 5 o ring 10 and seal tem 4 located in the bearing carrier Remove the input sun gear Item 16 from the input planet assembly 8 Install three 1 4 eyebolts into the three planet pins in the planet set Item 8 and with a piece of chain pull the planet set from the drum Inspect the planet set for wear and repair as needed See Servicing The Planetary Set section for dis assembly and repair Check the drum teeth for wear This wear can be measured as follows
11. lls for operation in temperatures outside this range contact Tulsa Winch for recommendations Gearbox oil is drained by first removing the level plug tem 35 in the center of the output shaft 6 The drain 35 is then removed by rotating the drum so that the plug is visible through the lower hole in the side plate 7 Screw in a piece of 1 black pipe to allow the oil to drain then with a 3 8 hex wrench remove the drain plug located inside of 1 pipe See Fig 2 Examine the used oil for signs of significant metal deposits and then dispose of it in a proper manner Remove 1 pipe Rotate drum so that the plug tem 35 is visible through upper hole in side plate Install 1 pipe and elbow through upper hole in side plate See Fig 3 Fill the gearbox with 1 quart of new SAE 90 EP gear lube Remove the 1 pipe and elbow Replace the plugs 35 Make sure the poppet breather tem 36 is not frozen and replace if necessary Drain the brake section by removing the drain plug tem 38 under the motor and the fill plug 37 above the motor See Fig 4 On some units the drain and fill plugs may be located on the edge of the motor cover Inspect the oil for signs of metallic particles and or burning and re install the drain plug Fill with 1 2 to 1 pint of SAE 20 20W motor oil WARNING Do not use EP type gear lubes in the brake section of this winch EP lubes may prevent the clutch from loc
12. om 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 The brake valve is modulated by sensing pressure on the other main line the line from the directional control valve to the motor Also any time there is sufficient pressure to modulate the brake valve this same pressure releases the multiple disc brake HYDRAULIC SCHEMATIC QIL FROM CONTROL VALVE sen eee eee oo eeu See QIL TO CONTROL VALVE V GEG pes A L gp p gt anne nae on HIGH PRESSURE LOW PRESSURE OIL CONTROL VALVE ry yy CEEE PTT yy OIL FROM CONTROL VALVE 2 p AK WW MAINTENANCE Tulsa Model 506W planetary winches like any other pieces of machinery need to be periodically serviced and well maintained to insure their proper operation Good maintenance consists of three steps 1 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 including changing the oil in both the gearbox and the brake section Severity of use will determine the need for oil changes but it sho
13. the proper equipment not this 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 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 Winch operators must be trained in the proper safe operation of the winch 2 INTRODUCTION AND THEORY OF OPERATION LN NIN N she 2 T N wo LAK w IOS i N i SY 6 KIS The 506W planetary winch design is composed of an input from a high torque low speed geroler motor or a high speed gear or piston motor driving through a multiple disc brake through a planet set to the cable drum The multiple disc brake is spring applied and hydraulically released through a port in the brake housing 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 During payout a brake valve is used to prevent the load fr
14. to base plate 15 Using two capscrews 43 attach side plate to support rods 19 Carefully turn winch over so motor side is up Install the planet carrier tem 8 using the same eyebolts and chain used to disassemble the unit making sure the planet set is seated against retaining ring tem 7 properly Install the sun gear tem 16 into the planet set Install a new oring 10 and if necessary bearing tem 5 8 seal 4 into the bearing carrier 9 Grease the oring and seal on the bearing carrier and install the bearing carrier into the drum It must be installed with the o ring nearest the motor end Place the brake sub assembly into the side plate tem 2 making sure that the pilot of the brake section aligns with the bore in the bearing carrier and that the bolts for the motor are oriented properly Install one capscrew 41 and five nuts 40 tighten capscrew and nuts evenly to 100 to 110 ft lb torque Also make sure that the level and vent plugs in the cover are properly oriented Install a new o ring or gasket on the face of the motor and re install the motor counterbalance valve assembly then re connect the hose Fill both the gearbox and the brake section with the proper amount and type of lubricants as discussed in the Lubrication section SERVICING THE MOTOR Tag brake line for proper re installation and remove them from the motor and counterbalance block
15. uld be checked at a minimum of every 500 operating hours and changed every 1000 operating hours 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 crane or other equipment which this winch is mounted on is subject to standards for this type of inspection then those standards must be followed If oil changes reveal significant metallic particles then a teardown and inspection must be made to determine the source of wear WIRE ROPE Wire rope should be installed as shown in the drawing below Note that the wedge will satisfy cable diameters from 7 16 to 5 8 depending on how it is installed in the cable drum 7 18 1 2 To ENO 151 SHL 8 5 91 6 LUBRICATION The hydraulic system 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 Tulsa Model 506W Winches are shipped from the 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 ca
Download Pdf Manuals
Related Search