Dover TWG TULSA WINCH 707W User manual

http://www.tulsawinch.com
SEL-0088-001
REV 1 July 2020
TABLE OF CONTENTS
SAFETY NOTES ...........................................................................................................................2
INTRODUCTION 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...........................................................................................15
BILL OF MATERIAL...................................................................................................................16
EXPLODED ISOMETRIC ASSEMBLY DRAWING.........................................................................18

2
safety notes
FAILURE TO HEED THE FOLLOWING WARNINGS MAY
RESULT IN SERIOUS INJURY OR DEATH!
•Operators must be trained in the proper, safe operation of the hoist.
•Hoists are not to be used to lift, raise, or move people. If your task involves lifting or moving
people, you must use the proper equipment, not this hoist.
•Cable anchors 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 can cause failure of the cable or the hoist.
•Make sure that all equipment, including the hoist and cable, are maintained properly.

3
INTRODUCTION AND THEORY OF OPERATION
The planetary hoist is designed to utilize a geroler, gear, or piston motor, driving through a
multiple-disc oil brake, through a planetary gearset to the cable drum.
The multiple-disc oil 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
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 sensing pressure on the other main line, the line from the directional control valve to
the motor. Additionally, any time there is sufficient pressure (330 PSI ±10%) to modulate the
brake valve; this same pressure releases the brake.

4
HYDRAULIC SCHEMATIC

5
MAINTENANCE AND SERVICE
For safe and consistent operation of TULSA WINCH hoists, swing drives, and winches, a regular
program of preventive maintenance is strongly recommended. Regular oil changes with the
correct oil for the ambient temperature conditions and an annual inspection of the wear
components will help ensure a long life for your planetary geared products.
Maintenance Scheduling
The owner is to ensure proper inspection intervals, in compliance with the API RP 2D Section 4
requirements or the ANSI B30.5, 5-2.3, and will review hoist usage categories on a periodic
basis. A Qualified Inspector should perform all maintenance and inspections.
•For hoists in occasional use, less than 10 hours per 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
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 pre-use
inspection, monthly inspection, quarterly inspection, and an annual 12-month inspection.
Oil Level Maintenance
Tulsa Winch recommends that the oil level in the gearbox and brake housing be checked and
adjusted as part of the pre-use inspection. If the oil level drops frequently or oil leakage is
detected during an inspection, maintenance should be performed to correct any problems.
Oil Change Interval
The oil in the gearbox and brake sections should be changed every 1000 hrs or 6 months of
usage.

6
MOBIL 1 SYNTHETIC ATF
SAE 20W20
SAE 90W AGMA 4 EP
MOBIL SHC 75W90
MOBIL SHC 524
RECOMMENDED OIL
All oils must meet MIL-PRF2105E. Substitution from a reputable manufacturer is allowed as
long as type and grade are maintained.
OIL CAPACITY
GEARBOX 1.00 QUART
BRAKE .25 QUART
Do not use EP type gear lubes in the brake section of this winch. EP lubes
may prevent the clutch from locking up, which, in turn causes the load to fall,
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 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 90 Extreme Pressure (EP) gear lube in the gearbox
and lightweight non-EP oil in the brake section. This oil and gear lube should be satisfactory for
operation in ambient temperatures from -10º F (-23º C) to +130º F (+55º C).

7
OIL CHANGE
Gearbox oil is drained by rotating the drum so that the drain plug (Item 33) is visible through the
lower hole in the side plate
(Item 50) (See Fig 1) . Screw in a piece of 1" pipe to allow the oil to
drain, and then with a hex wrench remove the drain plug located inside of the 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 the 1” pipe.
Rotate the drum so that the port is visible through the upper hole in the side plate
. Install a 1” pipe
with elbow into the upper hole in the side plate
(See Fig. 3) . Remove the plug (Item 33) located in
the center of the shaft. Fill the gearbox with 1.00 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 metallic particles and/or
burning and reinstall the drain plug. Fill with .25 quart of non-EP oil and reinstall the vent
(Item
30). See Oil Chart Pg. 6 this manual for recommended oil type and grade for your application.
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.

8
DISASSEMBLY
1. Drain the oil from the gearbox and brake sections using the instructions on page 7.
2. Stand the hoist on its end with the motor pointing up.
3. Disconnect the hose
(Item 46) connected to the brake housing (Item 21) . Remove the motor
and counterbalance valve assembly from the hoist by removing two capscrews
(Item 51) and
washers
(Item 52) . See Servicing The Motor section on page 10 for motor and counterbalance
valve disassembly.
4. Remove the brake subassembly from the hoist by removing eight capscrews
(Item 9) holding
the brake housing to the side plate
(Item 1). See Servicing The Brake section on page 11 for
brake repair
.
5. Remove the side plate
(Item 1) by removing twelve capscrews (Items 2 & 60) .
6. Lift the bearing carrier
(Item 26) out of the drum (Item 5) . Inspect the bearing (Item 28) for
signs of pitting or spalling and if necessary, replace the bearing and seal
(Item 7-3) .
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 and repair.
9. Remove the drum
(Item 5) by lifting straight up and off of the output shaft (Item 32). Inspect
the gear teeth for excessive wear and replace if necessary. Inspect the bearing
(Item 28) for
signs of spalling or pitting and, if necessary, replace the bearing and seal
(Item 7-3) .
10. Inspect the retaining ring
(Item 3) on the output shaft to ensure that it is still in the groove and
is not bent, and replace if necessary.
11. Inspect the shaft
(Item 32) for wear or damage and, if necessary, remove it from the side plate
(Item 50) by removing six capscrews (Item 62).

9
ASSEMBLY
1. Thoroughly clean all parts. Replace those that show wear or damage.
2. Inspect the drum
(Item 5) for structural integrity and the gear teeth for excessive wear, then
replace if necessary.
3. Attach the output shaft
(Item 32) to the side plate (Item 50) with six capscrews (Item 62) ,
making sure the vent
(Item 30) is oriented properly, then torque them to specification (see
Torque Specifications Chart on page 15 of this manual)
.
4. Install the retaining ring
(Item 3) onto the output shaft (Item 32) .
5. Attach the rods
(Item 43) and base (Item 12) to the side plate (Item 50) with twelve capscrews
(Items 2 & 60) . Torque to specification (see Torque Specifications Chart on page 15 of this
manual)
.
6. If necessary, install a new bearing
(Item 28) and oil seal (Item 7-3) into the drum.
7. Lay the unit down so that the rods
(Item 43) and base (Item 12) are pointing up. Set the drum
(Item 5) onto the output shaft (Item 32) being careful not to damage the seal (Item 7-3) .
8. Install the planet gearset
(Item 4) into the drum (Item 5) , making sure it’s installed correctly
onto the shaft
(Item 32) .
9. Insert the sun gear
(Item 8) into the planet gearset (Item 4) . The slot in the sun gear must be
installed down, facing the output shaft.
10. Install a new o-ring
(Item 7-6) and, if necessary, a new bearing (Item 28) and seal (Item 7-3)
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 twelve capscrews
(Items 2 & 60) . Torque to specification (see Torque
Specifications Chart on page 15 of this manual).
12. Install the brake subassembly into the side plate
(Item 1) , making sure that the pilot of the
brake housing
(Item 21) aligns with the bearing (Item 28) and seal (Item 7-3) in the bearing
carrier
(Item 26) and that the holes for the motor are in the correct orientation. Also, make
sure that the level and vent plugs in the cover are properly oriented. Install eight capscrews
(Item 9) and torque them to specification ( see Torque Specifications Chart on page 15 of this
manual
).
13. Install a new o-ring
(Item 7-1) on the face of the motor and re-install the motor/counterbalance
valve assembly. Install two capscrews
(Item 51) and washers (Item 52) and torque them to
specification
(see Torque Specifications Chart on page 15 of this manual) .
14. Reconnect the hose
(Item 46) to the brake housing (Item 21).
15. Fill both the gearbox and the brake section with the proper amount and type of lubricants as
instructed in the
Recommended Oil section on page 6 of this manual.

10
45
44
51
52
49
46
7-1
CONFIGURATION
A
CONFIGURATION
B
VIEW FOR 2 SPEED
SERVICING THE MOTOR
1. Remove the hose (Item 46) and counterbalance block (Item 42) from the motor assembly.
2. Remove the counterbalance valve from the block
(Item 42) and inspect the small metering hole
located on the side of the valve to make sure it is not obstructed. Also, inspect the o-rings for
damage and replace if necessary.
3. Motors and counterbalance components are not serviceable in the field. Return them to an
authorized dealer for service.

11
SERVICING THE BRAKE
1. Evenly remove four capscrews (Item 11) holding the brake cover (Item 20) in place. Spring
pressure will raise the cover as the capscrews are loosened. Remove the cover from the brake
housing.
2. Remove the springs
(Item 24) from the piston (Item 10) and check the free height. Each
spring should measure at least 1.200 inches with no force on them.
3. Remove the brake piston
(Item 10) 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 shop air to slowly pressurize the brake cavity until the piston is out of the bore.
4. Remove the brake driver/clutch assembly
(Items 13, 14, 15, 17, 34, and 38) from the brake
housing
(Item 21) .
5. Remove the stator plates
(Item 19) and friction discs (Item 18) from the brake housing and
check them for excessive wear, then replace if necessary. Additionally, 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 inches thick and stator plates should measure no less than 0.064
inches thick.
6. If necessary, remove the seal
(Item 7-5) from the brake housing.
7. If the brake housing
(Item 21) is removed from the hoist, examine the journal on the brake
housing where the seal
(Item 7-3) 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 the proper direction in order for the hoist to function properly. Inspect the surface on
the input and brake drivers
(Items 13 & 38) where the clutch (Item 34) runs. If there is any
pitting or spalling on the drivers then both it and the clutch must be replaced.
9. Re-assemble the driver/clutch assembly, making sure that the clutch is installed properly.
10. Install a new seal
(Item 7-5) into the brake housing. If the brake housing is removed from the
hoist, temporarily install the input sun gear
(Item 8) into the brake housing and slide the
driver/clutch assembly onto the sun gear spline.
11. Install the stator plates
(Item 19) and friction discs (Item 18) 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.
12. Coat the new oil seals
(Item 7-4) with light oil and install onto the piston (Item 10) . See Fig. 5
for proper installation
.
13. Carefully install the piston
(Item 10) into the brake housing (Item 21) and gently tap it down
until it is seated.
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.

12
15. Coat the new o-ring
(Item 7-2) 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) . 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

13
SERVICING THE PLANETARY SET
1. Remove the retaining rings from the planet pins.
2. Remove the pins from the carrier by carefully tapping them out.
3. Remove the planet gears, washers and bearings from the carrier.
4. Inspect the pins, bearings, 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 rings onto the planet pins.

14
TROUBLESHOOTING
Hoist won’t hold load
Possible Solutions:
1. There is excessive back pressure in the hydraulic system. Check the system for line
restrictions and reduce the back pressure.
2. The brake discs are worn. Replace the brake discs. Friction discs should measure no less
than 0.055 inches thick and the stator plates should measure at least 0.064 inches thick.
3. The brake clutch is slipping due to wear of either driver and/or clutch. Inspect the driver
components for wear and replace if necessary.
Hoist unable to lift load
Possible Solutions:
1. The 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)
. Remove the cartridge and clean it.
Oil leaks from motor-side vent
Possible Solutions:
1. The motor shaft seal may have failed. Have the seal replaced and reduce the back pressure
if that was a cause of the seal failure.
2. The brake pistons o-ring seals may have failed. Service the brake section and replace any
worn parts found.

15
TORQUE SPECIFICATIONS CHART
Dry Plated Lubricated Dry Plated Lubricated
SAE
Grade 5 SAE Grade 5 SAE Grade 5 SAE Grade 8 SAE Grade 8 SAE Grade 8
Nominal Size Torque
*(Ft-Lbs) Torque *(Ft-Lbs) Torque *(Ft-Lbs) Torque *(Ft-Lbs) Torque *(Ft-Lbs) Torque *(Ft-Lbs)
1/4 20 8 6 5 12 9 7
1/4 28 10 7 6 14 10 8
5/16 18 17 13 10 25 18 15
5/16 24 19 14 11 27 20 16
3/8 16 31 23 19 44 33 26
3/8 24 35 26 21 49 37 30
7/16 14 49 37 30 70 53 42
7/16 20 55 41 33 78 58 47
1/2 13 76 57 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 16 297 223 178 420 315 252
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
1-1/4 7 1120 840 672 1817 1363 1090
1-1
/
4 12 1241 930 745 2012 1509 1207
T = BOLT TORQUE (LB. FT.) T = (KWD) / 12
K = TORQUE COEFFICIENT (K = 0.20 DRY K = 0.15 PLATED K = 0.12 LUBRICATED)
W = PRELOAD TENSION
D = NOMINAL BOLT SIZE (IN.) * ALL TORQUE VALUE TOLERANCES ARE ± 5%

16
BILL OF MATERIAL
SEQ QTY P/N DESCRIPTION NOTES
1a 1 42432 SIDE PLATE
1b 1 42440 SIDE PLATE BRAKE SIDE
(SEE PICTORAL FOR DESCRIPTION)
2 20 44581 CAPSCREW
3 1 29973 RETAINING RING
4 1 4412 PLANET GEARSET
4-1 1 42176 CARRIER
4-2 6 30484 BEARING
4-3 3 42185 PLANET GEAR
4-4 6 28771 WASHER
4-5 3 41715 RETAINING RING
4-6 3 42184 PLANET PIN
4-7 1 44067 THRUST PLATE
5a 1 42179 DRUM Ø15.00 FLANGE
5b 1 42443 DRUM Ø14.25 FLANGE
7a 1 4314 SEAL KIT
7b 1 4335 SEAL KIT FOR CHARLYNN 4K SERIES MOTOR
8 1 44516 SUN GEAR
9 8 40410 CAPSCREW
10 1 41738 BRAKE PISTON
11a 4 31456 CAPSCREW 1.50” LENGTH
11b 4 20525 CAPSCREW 2.00” LENGTH
12a 1 42347 BASE FOUR MOUNTING HOLES
12b 1 42442 BASE EIGHT MOUNTING HOLES
13 1 41740 BRAKE DRIVER
14 2 41723 RACE
15 2 26980 RETAINING RING
17 2 41743 BUSHING
18 5 32765 FRICTION DISC
19 6 42148 STATOR PLATE
20a 1 42172 BRAKE COVER
20b 1 42401 BRAKE COVER
20c 1 42552 BRAKE COVER (SEE PICTORAL FOR DESCRIPTION)
21 1 42171 BRAKE HOUSING
24 12 41718 BRAKE SPRING
25a 1 42286 COUNTERBALANCE VALVE FOR CHARLYNN 2 SPD. MOTOR
25b 1 42554 COUNTERBALANCE BLK W/ VALVE FOR CHARLYNN 4K SERIES MOTOR
26 1 41752 BEARING CARRIER
28 2 34550 BEARING
29 1 41756 CABLE WEDGE
30 2 13050 BREATHER
32 1 42177 SHAFT
33 2 41719 O-RING PLUG
34 1 41759 CLUTCH
38 1 44584 INPUT DRIVER
40 1 32220 PIPE PLUG
42a 1 40637 COUNTERBALANCE BLOCK CHARLYNN 2K SERIES, 3 MOUNT HOLES
42b 1 42967 COUNTERBALANCE BLOCK CHARLYNN 2K SERIES-2 SP, 4 MOUNT HOLES
42c 1 43883 COUNTERBALANCE BLOCK CHARLYNN 2K SERIES, 3 MOUNT HOLES
43 2 42188 SUPPORT ROD
44a 1 42189 HYDRAULIC MOTOR CHARLYNN 2K SERIES, 14.9 CU-IN
44b 1 42968 HYDRAULIC MOTOR CHARLYNN 2K SERIES, 18.7 CU-IN
44c 1 44513 HYDRAULIC MOTOR CHARLYNN 2K SERIES-2 SP, 24.0/12.0 CU-IN
44d 1 42549 HYDRAULIC MOTOR CHARLYNN 4K SERIES, 24.0 CU-IN

17
SEQ QTY P/N DESCRIPTION NOTES
45 2 41838 STRAIGHT ADAPTER QUANTITY VARIES PER ASSEMBLY
46a 1 42031 HOSE ASSEMBLY 18.00” LENGTH
46b 1 42496 HOSE ASSEMBLY 19.50” LENGTH
46c 1 42494 HOSE ASSEMBLY 10.50” LENGTH
46d 1 42551 TUBING FOR CHARLYNN 4K SERIES MOTORS
49 1 41873 SWIVEL ADAPTER
50a 1 42433 SIDE PLATE
50b 1 42441 SIDE PLATE
50c 1 42477 SIDE PLATE
OUTPUT SIDE
(SEE PICTORAL FOR DESCRIPTION)
51a 2 43857 CAPSCREW
52 2 43856 LOCKWASHER
55a 3 43858 CAPSCREW
55b 8 31558 CAPSCREW
55c 4 43111 CAPSCREW MATCH QTY WITH PROPER MOUNT
57 1 12208 BUSHING
60 4 44579 CAPSCREW
62 8 44580 CAPSCREW
64 1 41879 STRAIGHT ADAPTER
70 1 4190 CABLE PACKER ASSEMBLY
70-1 2 42515 BEARING
70-2 1 42584 ARM
70-3 2 42585 ROLLER
70-4 1 42586 ROLLER
70-5 2 42587 CAPSCREW
70-6 2 42516 BEARING
70-7 1 42425 LEFT SPRING
70-8 1 42533 RIGHT SPRING
74 1 43446 COIL
83 1 43445 SPOOL VALVE
84 1 42392 O-RING PLUG
85 1 42287 CAVITY PLUG

18
EXPLODED ISOMETRIC ASSEMBLY DRAWING
TWG
PO Box 1130
Jenks OK 74037-1130 USA
Phone: [phone]
www.dovertwg.com