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Dover TWG TULSA WINCH 1200W, Service Manual

The Dover TWG TULSA WINCH 1200W is a powerful and reliable winch for various applications. Ensure proper maintenance and repairs with the free Service Manual available for download from manualshive.com. Get the manual to keep your winch in top condition and maximize its performance.

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16

BILL OF MATERIAL 

 

 
 

SEQ 

 

QTY 

 

P/N 

 

DESCRIPTION 

 NOTES 

1a 

 1  42394  SIDE 

PLATE  

1b 

 1  4252  SIDE 

PLATE  

1c 

 1  43170  SIDE 

PLATE  

1d 

 1  42518  SIDE 

PLATE  

1e 

 1  42484  SIDE 

PLATE  

BRAKE SIDE 

(SEE PICTORAL FOR IDENTIFICATION) 

2 

 20  29792  CAPSCREW  

 

2* 

 16  29792  CAPSCREW 

  

ALTERNATE QTY FOR 4252/4508 SIDEPLATES 

3 

 1  29973  RETAINING 

RING  

 

4a 

 1  4384  

OUTPUT GEARSET  

 

FOR 1221W, 1229W, 1241W 

4a-1 

 1  41755  CARRIER  

 

4a-2 

 3  41728  

OUTPUT PLANET GEAR 

 

 

4a-3 

 3  41747  PLANET 

PIN  

 

4a-4 

 3  41716  RETAINING 

RING  

 

4a-5 

 1  44067  THRUST 

PLATE  

 

4a-6 

 6  41717  BEARING  

 

4a-7 

 3  41739  SPACER  

 

4a-8 

 6  939249  WASHER  

 

4b 

 1  4391  

OUTPUT GEARSET  

 FOR 

1259W 

4b-1 

 1  41754  CARRIER  

 

4b-2 

 3  41729  

OUTPUT PLANET GEAR 

 

 

4b-3 

 3  41747  PLANET 

PIN  

 

4b-4 

 3  41716  RETAINING 

RING  

 

4b-5 

 1  44067  THRUST 

PLATE  

 

4b-6 

 6  41717  BEARING  

 

4b-7 

 3  41739  SPACER  

 

4b-8 

 6  939249  WASHER  

 

5a 

 1  41731  DRUM 

  

Ø16.38 FLANGE, Ø9.75 BARREL 

5b 

 1  42128  DRUM 

  

Ø15.00 FLANGE, Ø9.75 BARREL 

5c 

 1  42510  DRUM  

Ø13.75 FLANGE, Ø9.75 BARREL 

5d 

 1  42413  DRUM  

Ø16.38 FLANGE, Ø10.63 BARREL 

5e 

 1  43171  DRUM 

  

Ø14.00 FLANGE, Ø10.63 BARREL 

6 

 2  41722  RACE  

 

7a 

 1  4322  SEAL 

KIT  

FOR 81462001 ASSEMBLY  

(NO MOTOR OR BRAKE) 

7b 

 1  4316  

SEAL KIT  

 

FOR GEROLER MOTOR 

7c 

 1  4321  

SEAL KIT  

 

FOR SINGLE SPEED GEAR MOTOR 

7d 

 1  4339  SEAL 

KIT  

FOR TWO SPEED GEAR MOTOR 

8a 

 1  41734  

INPUT SUN GEAR  

 

FOR 1241W AND 1259W 

8b 

 1  41735  

INPUT SUN GEAR 

 FOR 

1229W 

8c 

 1  41736  

INPUT SUN GEAR 

 FOR 

1221W 

9 

 14  20524  CAPSCREW  

 

10 

 1  42942  BRAKE 

PISTON  

 

11 

 4  10381  CAPSCREW  

 

12a 

 1  42393  BASE  

8 Ø.656 MOUNTING HOLES 

12b 

 1  43132  BASE  

4 Ø.812 MOUNTING HOLES                

FOR 4252/4508 SIDEPLATES 

12c 

 1  42520  BASE  

4 Ø.687 MOUNTING HOLES 

12d 

 1  42266  BASE  

4 Ø.812 MOUNTING HOLES 

13 

 1  43453  BRAKE 

DRIVER  

 

14 

 2  41723  RACE  

 

15 

 2  26980  RETAINING 

RING  

 

16a 

 1  44316  

OUTPUT SUN GEAR 

 

FOR 1221W, 1229W, 1241W 

16b 

 1  44370  

OUTPUT SUN GEAR 

 FOR 

1259W 

17 

 2  41743  BUSHING  

 

18 

 7  32765  FRICTION 

DISC  

 

19 

 8  42148  STATOR 

PLATE  

 

Summary of Contents for TWG TULSA WINCH 1200W

Page 1: ...AND THEORY OF OPERATION 3 HYDRAULIC SCHEMATIC 4 MAINTENANCE AND SERVICE 5 WIRE ROPE 7 DISASSEMBLY 8 ASSEMBLY 9 SERVICING THE MOTOR 10 SERVICING THE BRAKE 11 SERVICING THE PLANETARY SETS 13 TROUBLESHO...

Page 2: ...on hoists are not designed to hold the rated load of the hoist You must keep at least five 5 wraps of cable on the drum to ensure that the cable doesn t come loose Stay clear of suspended loads and o...

Page 3: ...e brake When the load comes to a stop the cam clutch locks up and the brake prevents the load from moving During payout a brake valve is used to prevent the load from moving faster than desired This b...

Page 4: ...4 HYDRAULIC SCHEMATIC...

Page 5: ...month API RP 2D recommends a pre use inspection and an annual 12 month inspection based on average use over a quarter For hoists in moderate use more than 10 but less than 50 hours per month API RP 2D...

Page 6: ...ll resulting in property damage personal injury or death The hydraulic system should use only high quality hydraulic fluid from reputable suppliers These oils should contain additives to prevent foami...

Page 7: ...the side plate See Fig 3 Fill the gearbox with 1 00 quart of EP 90 oil Remove the pipe and elbow then replace the plug Item 33 See the Oil Chart on page 6 of this manual for the recommended oil type a...

Page 8: ...place the bearing and seal Item 7 4 7 Remove the thrust washer Item 6 and input sun gear Item 8 from the input planet gearset Item 36 Inspect for damage and replace if needed 8 Remove the input planet...

Page 9: ...place Install the thrust washer into the output gearset Item 4 and then insert the output sun gear Item 16 The slot in the sun gear must be installed facing the output shaft 10 Install the input plan...

Page 10: ...hole located on the side of the valve to make sure it is not obstructed Also inspect the o rings Item 7 10 for damage and replace if necessary 4 Remove the fitting Item 60 and inspect the check valve...

Page 11: ...brake housing Item 21 is removed from the hoist examine the journal on the brake housing where the seal Item 7 4 runs for wear If severely worn replace the brake housing 9 Carefully disassemble the b...

Page 12: ...in a horizontal position coat the bottom of each spring with chassis lube to keep it in position 17 Coat the new o ring Item 7 3 with light oil and install it into the groove on the brake cover Item 2...

Page 13: ...d replace if necessary 5 On output planet gearsets note that two bearings with a spacer between them are used 6 Before reassembly be sure to insert the thrust plate into the carrier 7 To reassemble be...

Page 14: ...proper lifting Increase the relief pressure setting 2 The load being lifted may be more than the winches rating Verify weight and reduce the load or re rig it to increase mechanical advantage Hoist u...

Page 15: ...7 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 2...

Page 16: ...31 DRUM 16 38 FLANGE 9 75 BARREL 5b 1 42128 DRUM 15 00 FLANGE 9 75 BARREL 5c 1 42510 DRUM 13 75 FLANGE 9 75 BARREL 5d 1 42413 DRUM 16 38 FLANGE 10 63 BARREL 5e 1 43171 DRUM 14 00 FLANGE 10 63 BARREL 6...

Page 17: ...E 36b 6 3 30484 BEARING 36b 7 6 28771 WASHER 36c 1 4139 INPUT GEARSET FOR 1241W 36c 1 1 41766 CARRIER 36c 2 3 41763 PLANET GEAR 36c 3 3 41760 PLANET PIN 36c 4 3 41715 RETAINING RING 36c 5 1 41769 THRU...

Page 18: ...1 12208 BUSHING 58a 1 42022 SINGLE SPEED GEAR MOTOR 58b 1 42023 SINGLE SPEED GEAR MOTOR 58c 1 42521 SINGLE SPEED GEAR MOTOR 58d 1 43126 SINGLE SPEED GEAR MOTOR 58e 1 42021 SINGLE SPEED GEAR MOTOR CONT...

Page 19: ...19 EXPLODED ISOMETRIC ASSEMBLY DRAWING TWG PO Box 1130 Jenks OK 74037 1130 USA Phone 918 298 8300 www dovertwg com...

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