Dover TWG 250PR Betriebsanleitung

www.team-twg.com

SEL-0152-000

REV 1 JUNE 2015

Model 250PR

Service/Repair Manual

TABLE OF CONTENTS

SAFETY NOTES...........................................................................................................................................2

INTRODUCTION AND THEORY OF OPERATION .....................................................................................3

HYDRAULIC SCHEMATIC...........................................................................................................................4

MAINTENANCE AND SERVICE ..................................................................................................................5

TWG 250PR RECOMMENDED OILS ..........................................................................................................6

OIL CHANGE................................................................................................................................................7

DISASSEMBLY ............................................................................................................................................8

ASSEMBLY ..................................................................................................................................................9

SERVICING THE BRAKE...........................................................................................................................10

SERVICING THE BEARING AND PINION SECTION................................................................................12

SERVICING THE PLANETARY SETS.......................................................................................................13

TROUBLESHOOTING................................................................................................................................14

TORQUE SPECIFICATIONS CHART ........................................................................................................15

BILL OF MATERIAL...................................................................................................................................16

CROSS SECTIONAL ASSEMBLY DRAWING ..........................................................................................17

EXPLODED ASSEMBLY DRAWING.........................................................................................................18

INSTALLATION DRAWING........................................................................................................................19

SAFETY NOTES

FAILURE TO HEED THE FOLLOWING WARNINGS MAY

RESULT IN SERIOUS INJURY OR DEATH!

•Operators/Technicians must be trained in the proper, safe operation of the swing-drive gearbox.

•All shields and guards must be in place during operation of swing-drive gearbox.

•Be aware of and stay clear of all pinch points during operation of swing-drive gearbox.

•Boom must be stowed and properly secured while removing swing-drive gearbox.

•Avoid shock loads. This type of load could impose a torque many times the actual torque rating

of the swing-drive gearbox.

•Make sure that all equipment, including the swing-drive gearbox is maintained properly.

•Counterbalance valves are pre-set from the factory and must not be adjusted.

INTRODUCTION AND THEORY OF OPERATION

The TWG 250PR planetary gearbox is a hydraulically driven 2-stage planetary gearbox designed to

use a motor with SAE “A” 2-BOLT mount and 1.00” 6B spline shaft. This gearbox has a total ratio of

38:1.

The gearbox is designed to utilize a hydraulic motor, driving through a multiple-disc static oil brake,

into a pair of planetary gear sets to the output pinion.

The multiple-disc oil bath static park brake is spring applied and hydraulically released through a

port in the brake housing. The multiple-disc “service brake” is hydraulically applied through a port

in the brake housing.

During operation, dual counterbalance valves are used for dynamic braking to prevent the gearbox

from moving faster than desired. These counterbalance/brake valves partially block the main line

from the motor back to the directional control valve, allowing only a limited amount of hydraulic

fluid through the motor. The counterbalance valves are generally internally modulated by sensing

pressure on the supply line. Additionally, any time there is sufficient pressure to modulate the

counterbalance valves; this same pressure releases the static friction/stator style park brake.

HYDRAULIC SCHEMATIC

The TWG 250PR is equipped with a spring applied hydraulically released static “park brake” and an

optional integral hydraulically applied dynamic “service brake”. The park brake on this unit should

full release by pressurizing the “BR” port to 300 psi. The maximum pressure allowed into the park

brake is 3,000 psi. The service brake is applied by pressurizing the “BA” port while pressurizing the

“BR” port. The maximum pressure allowed into the service brake port is 1,000 psi. The service

brake can be cooled using a flow-thru cooling method by plumbing hydraulic oil into “BC IN” port

and plumbing “BC OUT” port back to tank. The maximum pressure allowed in the brake cavity (flow

thru cooling circuit) is 25 psi. Excessive pressure in the flow thru cooling circuit could damage the

oil seal separating the brake oil from the gearbox oil.

MAINTENANCE AND SERVICE

For safe and consistent operation of TWG hoists, gearboxes, and winches, a regular program of

preventive maintenance is strongly recommended. Regular oil changes with the correct oil and

frequency for the application and an annual inspection of the wear components will help ensure

a long life for your planetary geared products.

Maintenance Scheduling

Manufacturer recommends changing oil after first 50 hours of operation. All gearboxes require

the proper EP gear oil for lubrication. Some units may be equipped with a grease fitting for

lubrication of the output shaft bearings (pinion up applications). The shaft bearings should be

greased sparingly at every 50 operating hours with an EP lithium or GP bearing lube. For pinion

down applications, gearbox oil will lubricate shaft bearings

Oil Level Maintenance

Tulsa Winch recommends that the oil 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 (if applicable) should be changed every 1000 hrs or

6 months of usage.

TWG 250PR RECOMMENDED OILS

Choose the proper gearbox and brake oil from lists below.

FOR STANDARD TEMP APPLICATIONS -10˚F THRU 180˚F (-23˚C THRU 82˚C) oil temp.

*Gearbox oil (GL-5): API 80W/90 GL-5 (Or equivalent)

Super MP 75W-90 GL-5 (Original oil in unit from factory)

Century Unigear Semi-Synthetic 80W-90

Texaco Multigear SS 80W-90 GL-5

Chevron DELO 80W-90 GL-5

**Brake oil: Not applicable for this gearbox

FOR LOW TEMP APPLICATIONS -40˚F THRU 180˚F ( -40˚C THRU 82˚C) oil temp.

*Gearbox oil (GL-5): Mobil Delvac Synthetic 75W90 (Or equivalent)

Mobil Mobilube 1 SHC 75W90

CITGO, Syntetic Gear Lube 75W-90

Eaton, Roadranger EP75W-90

Mobil, Mobilube SHC 75W-90

Shell, Spirax® S 75W-90

Sunoco®, Duragear EP75W-90

Petro-Canada, Traxon E Synthetic 75W-90

**Brake oil: Not Applicable for this gearbox

*All gearbox oils must meet MIL-PRF2105 and GL-5 specifications.

** Brake oil is not applicable to units equipped with the “Flow Thru Brake Cooling” option.

Hydraulic oil is plumbed thru the brake on “Flow Thru Brake Cooling” option.

GEARBOX OIL CAPACITY

PINION UP

N/A

PINION DOWN

3.50 QTS

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. The hydraulic system

should be equipped with a return line filter capable of filtering 10 micron particles from the system.

OIL CHANGE

Gearbox oil is drained by removing the drain plug and vent.

Examine the used oil for signs of

significant metal deposits and then dispose of it in a proper manner.

Replace the drain plug. Fill the swing drive with the appropriate amount and type of oil and then

replace plug and vent.

See page 6 of this manual for the recommended oil type, amount and grade

for your application.

Gearbox oil level inspection is achieved by removing the dipstick and visually inspecting the oil level.

DISASSEMBLY

1. Remove the gearbox from the crane by securing the boom, removing the 20 mounting bolts

and any hydraulic hoses connecting the crane to the gearbox assembly.

2. Orient the gearbox vertical and drain the gear oil from the gearbox. See page 7 of this

manual.

3. Label and disconnect all hoses still attached to the gearbox.

4. Remove the hydraulic motor by removing the 2 bolts in the motor flange.

5. Remove the brake assembly from the gearbox by removing 20 bolts and washers (Item

16, 15). NOTE: Notice the orientation of the ports in relation to the drain and fill holes for

reassembly.

See Servicing The Brake section on page 10 for brake service or repair

6. Inspect the O-ring (Item 44) for damage and replace if necessary.

7. Remove the nylon thrust washer (Item 14) and sun gear (Item 13) from the input

planetary set (Item 11). Inspect for wear or damage and replace if needed.

8. Remove input planet gear assembly by pulling straight up and out of the ring gear (Item

12).

See Servicing The Planetary Set section on page 13 for disassembly and repair.

9. Remove the nylon thrust washer (Item 14) and sun gear (Item 18) from the output

planetary gear set (Item 10). Inspect for wear or damage and replace if needed.

10. Remove output planet gear assembly by pulling straight up and out of the ring gear

(Item 12).

See Servicing The Planetary Set section on page 13 for disassembly and

repair.

11. To service the pinion gear or pinion bearings see

Servicing The Pinion Gear/Bearings

section on Page 12 of this manual for disassembly and repair.

44 11 1213

ASSEMBLY

1. After servicing, inspecting and or repairing the Brake, Pinion Bearing and or the Planetary

Gear sub-assemblies start reassembly by positioning the Bearing/Pinion section in a pinion

down orientation.

2. Install new O-ring (Item 43) onto ring gear pilot on top of bearing housing (Item 1).

3. Next install the ring gear (Item 12) onto the bearing housing making sure to align dowel

pins with the appropriate dowel pin hole. Using a dead blow hammer tap ring gear into

position.

4. Insert the output planetary gearset (Item 10) into the ring gear making sure that it fully

engages the splines on the output pinion shaft (Item 2).

5. Install output sun gear (item 18) into output planet set (Item 10).

6. Place and center nylon thrust washer (Item 14) on top of output planet set (Item 10).

7. With nylon washer in place install the input planet set (Item 11) into the ring gear making

sure it fully engages the teeth on the output sun gear (Item 18).

8. Insert the input sun gear (Item 13) into the input gear set (Item 11). Turn sun gear by

hand to ensure the gearing rotates and is not bound up.

9. Place and center nylon thrust washer (Item 14) onto input planet set (Item 11).

10. Lubricate and install a new O-ring (Item 43) onto brake housing (Item 27).

11. While considering proper port orientation install the brake section sub-assembly onto ring

gear (Item 12) and input sun gear (Item 13).

12. Install the 20 ring gear bolts and washers (Items 15 and 16). Tighten to spec. See page 15

for Torque Specifications Chart.

SERVICING THE BRAKE

1. Evenly remove the six bolts (Item 26) attaching the brake housing (Item 27) to the brake

adapter (Item 19). Spring pressure will raise the brake housing as the bolts are loosened.

Remove the brake housing from the brake adapter.

2. Remove the piston (Item 28) from the brake housing (Item 27) by applying shop air to the

“BR” port.

3. Remove the brake shaft (Item 30), friction disc’s (Item 31), stator plates (Item 32) and

bearings (Item 29) from brake housing (Item 27).

4. Using a bearing puller remove the bearings (Item 29) from the brake shaft (Item 30).

5. Remove the friction disc’s (Item 31) and stator plates (Item 32) from brake shaft (Item 30)

and check them for excessive wear, then replace if necessary. Friction discs should measure at

least 0.075 inches thick and stator plates should at least than 0.045 inches thick.

6. Remove the spacer (Item 40).

7. If equipped with a “Service Brake”, remove the service brake piston by applying shop air to the

“BA” port.

8. Remove and inspect all brake springs (Item 25) for damage. Replace if necessary.

9. Remove the O-rings (Item 44) out of brake adapter (Item 19).

10. Remove the O-rings and backup rings (Items 45, 46, 47, 48) from the piston brake (Item

28).

11. Install a new bearing (Item 29) into the brake adapter (Item 19).

12. Install the brake springs (Item 25) into the spring pockets in brake adapter (Item 19).

13. Tap or press the brake shaft (Item 30) into the bearing in the brake adapter (Item 19).

Note: The 6 tooth spline should be oriented to engage with the hydraulic motor.

14. Install the O-ring (Item 44) onto the brake adapter (Item 19).

15. Install the O-ring and backup rings (Items 45, 46, 47 and 48) onto the O.D. and I.D. of the

piston brake. Note, the rectangular backup rings should be located on the outsides of the O-

rings as shown in the cross sectional drawing on the Pg. 11 of this manual. Lubricate the O-

ring and backup rings and place the piston onto the springs centering the piston in the brake

adapter.

16. Install the friction discs (Item 31) and stator plates (Item 32) into the piston over the brake

shaft (Item 30). Note, you will start with a friction disc and end with a friction disc.

17. Place the spacer (Item 40) into the piston on top of the friction/stator pack.

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