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14.

Install the springs

(Item 24)

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.

15.

Coat the new o-ring

(Item 7-4)

with light oil and install it into the groove on the brake cover

(Item 20)

16.

Install the cover

(Item 20)

onto the brake housing

(Item 21)

and draw it down evenly,

alternating between opposite capscrews

(Item 9)

and nuts

(Item 65)

. Make sure that the cover

is aligned properly with the brake housing in order to correctly orient the motor and vent/drain
plugs.

17.

Check the brake release with a portable hydraulic pump. Full release should be obtained at 330
PSI

10%.

FIG 5

Summary of Contents for TWG TULSA WINCH 506W

Page 1: ...N 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 SET 13 TROUBLESHOOTING 14 TORQUE SPECIFICATIONS CHART 14 BILL OF MATERIAL 16 EXPLODED ISOMETRIC ASSEMBLY DRAWING 18 ...

Page 2: ...s 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 of cable under tension A broken cable or dropped load can cause serious injury or death Avoid shock loads This type of load imposes a strain on the hoist many times the actual weight of the load and c...

Page 3: ...ke 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 brake valve partially blocks the main line from the motor back to the directional control valve allowing only a limited amount of hydraulic fluid through the motor The brake valve is then modulated by sensi...

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

Page 5: ...onth 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 recommends a pre use inspection quarterly inspection and an annual 12 month inspection based on average use over a quarter For hoists in heavy use more than 50 hours per month API RP 2D recommends a p...

Page 6: ...sulting 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 foaming and oxidation in the system All hoist hydraulic systems should be equipped with a return line filter capable of filtering 10 micron particles from the system Hoists are shipped from the factory with SAE...

Page 7: ...ated in the center of the shaft Fill the gearbox with 75 quart of EP 90 oil Remove the pipe and elbow then replace the plugs Item 33 See the Oil Chart on page 6 of this manual for the recommended oil type and grade for your application Drain the brake section by removing the drain plug Item 40 under the motor along with the vent Item 30 above the motor See Fig 4 Inspect the oil for signs of metall...

Page 8: ...f the drum Item 5 Inspect the bearing Item 28 for signs of pitting or spalling and if necessary replace the bearing and seal Item 7 8 7 Remove the sun gear Item 8 from the planet gearset Item 4 Inspect for damage and replace if needed 8 Remove the planet gearset Item 4 from the drum Inspect the gearset for wear and repair as needed See Servicing The Planetary Set section on page 13 for disassembly...

Page 9: ...ft 10 Install a new o ring Item 7 4 and if necessary a new bearing Item 28 and seal Item 7 8 into the bearing carrier Item 26 Grease the o ring and seal and install the bearing carrier into the drum 11 Position the side plate Item 1 on top of the rods Item 43 and base Item 12 Attach the side plate with eight capscrews Items 2 60 Torque to specification see Torque Specifications Chart on page 15 of...

Page 10: ... sure it is not obstructed Also inspect the o ring Item 7 3 for damage and replace if necessary 3 For special assembly 81697001 remove the check valve Item 58 and female connector Item 59 Inspect for damage and replace if necessary When replacing check valve be sure arrow is facing the counterbalance block during installation 10 4 Motors and counterbalance valves are not serviceable in the field R...

Page 11: ...ving the retaining ring Item 72 7 If the brake housing Item 21 is removed from the hoist examine the journal on the brake housing where the seal Item 7 8 runs for wear If severely worn replace the brake housing 8 Carefully disassemble the brake driver clutch and note the side in which the markings on the clutch Item 34 are facing The clutch assembly must be re assembled with the markings facing th...

Page 12: ...l it into the groove on the brake cover Item 20 16 Install the cover Item 20 onto the brake housing Item 21 and draw it down evenly alternating between opposite capscrews Item 9 and nuts Item 65 Make sure that the cover is aligned properly with the brake housing in order to correctly orient the motor and vent drain plugs 17 Check the brake release with a portable hydraulic pump Full release should...

Page 13: ...arings and gear bores for evidence of wear and replace if necessary 5 Before reassembly be sure to insert the thrust plate into the carrier 6 To reassemble be careful to line up the planet pins with the washers and bearings then press the knurled part of the pin into the carrier If the pins are not lined up properly the washers can be shattered during the pressing operation 7 Replace the retaining...

Page 14: ...he relief valve setting may be too low to allow proper lifting Increase the relief pressure setting 2 The load being lifted may be more than the hoists rating Verify weight and reduce the load or re rig it to increase mechanical advantage Hoist unable to lower load Possible Solutions 1 The counterbalance valve cartridge may have a plugged metering hole see page 10 for location of metering hole Rem...

Page 15: ...4 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 7 794 596 475 1288 966 772 1 1 8 12 890 668 534 1444 1083 866 1 1...

Page 16: ...OR PLATE 20a 1 42353 BRAKE COVER FOR ASSEMBLY 81691001 20b 1 42636 BRAKE COVER FOR ASSEMBLIES 81692001 AND 82026001 20c 1 42514 BRAKE COVER FOR ASSEMBLY 81697001 20d 1 43608 BRAKE COVER FOR ASSEMBLIES 81683001 AND 81693001 21 1 43509 BRAKE HOUSING 24 12 41718 BRAKE SPRING 25a 1 43893 COUNTERBALANCE VALVE STANDARD COMPONENT 25b 1 40434 COUNTERBALANCE VALVE FOR ASSEMBLIES 81692001 AND 82026001 26 1 ...

Page 17: ...ND 81691001 50c 1 42836 SIDE PLATE FOR ASSEMBLY 81697001 51a 2 31486 CAPSCREW STANDARD COMPONENT 51b 2 43857 CAPSCREW FOR ASSEMBLIES 81692001 AND 82026001 52 2 43856 LOCKWASHER 55a 4 42398 CAPSCREW STANDARD COMPONENT 55b 3 43858 CAPSCREW FOR ASSEMBLIES 81692001 AND 82026001 57 1 12208 BUSHING 58 1 42223 CHECK VALVE 59 1 43393 FEMALE CONNECTOR 60 6 30379 CAPSCREW 62 6 44580 CAPSCREW 64 1 42089 90 D...

Page 18: ...EXPLODED ISOMETRIC ASSEMBLY DRAWING 18 TWG PO Box 1130 Jenks OK 74037 1130 USA Phone 918 298 8300 www dovertwg com ...

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