Tulsa 3541RL Service Manual

Installation operating & maintenance manual (24 pages)

Operating and maintenance manual (16 pages)

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MODEL CODE .....................................................................................................................................................2

!WARNING!...........................................................................................................................................................3

INTRODUCTION AND THEORY OF OPERATION...........................................................................................4

MAINTENANCE ...................................................................................................................................................4

GENERAL DISASSEMBLY .................................................................................................................................5

A. MOTOR DISASSEMBLY.............................................................................................................................5

B. BRAKE SECTION DISASSEMBLY ............................................................................................................6

C. DRUM & INPUT GEAR SECTION DISASSEMBLY ..................................................................................7

D. OUTPUT GEAR SECTION DISASSEMBLY.............................................................................................8

E. PLANET SET DISASSEMBLY AND ASSEMBLY......................................................................................8

GENERAL ASSEMBLY .......................................................................................................................................9

F. OUTPUT GEAR SECTION ASSEMBLY ....................................................................................................9

G. DRUM & INPUT GEAR SECTION ASSEMBLY ..................................................................................... 10

H. BRAKE SECTION ASSEMBLY ............................................................................................................... 11

I. MOTOR SECTION ASSEMBLY................................................................................................................ 12

TROUBLE SHOOTING..................................................................................................................................... 13

3541RL BILL OF MATERIAL............................................................................................................................ 14

3541RL SUB-ASSEMBLY BILL OF MATERIAL.............................................................................................. 15

VISCOSITY CHART.......................................................................................................................................... 16

TORQUE SPECIFICATIONS CHART ............................................................................................................. 17

G:\SERVICE LITERATURE\3541RL SERVICE LIT\Sel-0005.doc

Rev-0

3541RL

SERVICE MANUAL

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Summary of Contents for Tulsa 3541RL

Page 1: Table Of Contents
I. MOTOR SECTION ASSEMBLY........................ 12 TROUBLE SHOOTING............................. 13 TROUBLE SHOOTING............................. 13 3541RL BILL OF MATERIAL..........................14 3541RL BILL OF MATERIAL..........................14 3541RL SUB-ASSEMBLY BILL OF MATERIAL....................15 3541RL SUB-ASSEMBLY BILL OF MATERIAL....................15 VISCOSITY CHART............................16 VISCOSITY CHART............................16 TORQUE SPECIFICATIONS CHART ......................17 TORQUE SPECIFICATIONS CHART ......................
Page 2: Model Code
M ODEL CODE 3 5 4 1 RL A L O C D W E BASIC MODEL A OR B DRUM WIDTH LEFT/RIGHT MOUNT SPOOL OVER/UNDER DRUM CLOSE COUPLED MOTOR OPTION...
Page 3: Warning
FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH. 1. Tulsa Winches are not to be used to lift, hoist, or move people. If your task involves lifting or moving people, you MUST use the proper equipment, not this winch.
Page 4: Introduction And Theory Of Operation
Tulsa 3541RL series of winches are shipped from the factory with SAE 90 EP gear lube in the gearboxes and automatic transmission fluid in the brake section. This oil should be satisfactory for operation in ambient temperatures from -10°F to +110°F.
Page 5: General Disassembly
GEN ERAL DI SASSEM BLY A. MOTOR SECTION DISASSEMBLY 3. Remove the capscrews (item 71) holding 1. Drain the oil from the brake assembly by motor in place. removing the plug (item 32) from brake cover 4. Grasp the motor and remove from winch. (item 28).
Page 6: Brake Section Disassembly
B. BRAKE SECTION DISASSEMBLY Evenly remove the four capscrews (item 49) check them for excessive wear. Replace if that hold the brake cover in place. Spring necessary. Be sure to check the top stator pressure will raise the cover up as the plate for scoring caused by the removal of the capscrews are loosened.
Page 7: Drum & Input Gear Section Disassembly
C. DRUM & INPUT GEAR SET DISASSEMBLY 1. Remove all tubing and hoses attached to the seal (item 13), o-ring (item 11) and bearing motor (item 33) and brake housing (item 14). (item 12) for damage or wear, replace if (Note the location of tubing, hoses and fittings necessary.
Page 8: Output Gear Section Disassembly
D. OUTPUT GEAR SECTION DISASSEMBLY 1. With winch positioned horizontally drain the oil 2. Inspect the o-ring (item 77) and the outer race by removing the plug (item 79) at the bottom of (item 7), replace if necessary. the gear cover. To disassemble the output 3.
Page 9: General Assembly
GEN ERAL ASSEM BLY F. OUTPUT GEAR SECTION ASSEMBLY 1. Lubricate and insert inner race (item 7) into 4. lubricate and install outer race (item 7) into recess located in gear housing (item 80) recess located on output gear set. 2.
Page 10: Drum & Input Gear Section Assembly
G. DRUM & INPUT GEAR SET ASSEMBLY 1. Thoroughly clean all parts. Replace those 7. Lubricate and Insert thrust washer (item 9) into which show wear. Lubricate all oil seals and drum and locate in recess on input gear set o-rings before assembly.
Page 11: Brake Section Assembly
H. BRAKE SECTION ASSEMBLY 1. Lubricate and install inner piston (item 17) into brake piston (item 29) with the o-ring side brake housing (item 14). toward the flange of the piston. 2. Insert sliding clutch (item 27) into bore of inner 8.
Page 12: Motor Section Assembly
I. MOTOR SECTION ASSEMBLY Insert motor (item 33) into brake cover (item 2. Attach all tubing and hoses. 28) making sure that ports are oriented 3. Fill brake section with proper amount of ATF correctly. Install capscrews (item 71) with fluid.
Page 13: Trouble Shooting
T ROU BLE SH OOT I N G 1. PROBLEM: Winch won’t hold load. SOLUTION: a. Excessive back pressure in the system. Check the system for restrictions and reduce the backpressure. b. Brake discs are worn out. Replace brake discs. c.
Page 14: 3541Rl Bill Of Material
3 5 4 1 RL BI LL OF M AT ERI AL ITEM NO. PART NO. QTY. DESCRIPTION 42814 DRUM 42812 SHAFT 42827 30567 RETAINING RING 30385 BEARING, BALL 42828 SEAL, OIL 42839 RACE 4217 INPUT GEAR SET 41722 RACE 42203 CARRIER BEARING 939452...
Page 15: 3541Rl Sub-Assembly Bill Of Material
42599 ADAPTER, STRAIGHT 42600 ADAPTER, SWIVEL 90 DEG. 40146 CAPSCREW 21723 21106 WASHER 42283 CAPLUG 42517 CAPSCREW 42618 ADAPTER, TEE 42494 HOSE ASSEMBLY 42620 ADAPTER, REDUCER 42033 TEE, SWIVEL NUT 41668 CAPLUG 42841 O-RING 4101 BUSHING & BREATHER 32220 PLUG 42802 GEAR HOUSING 41641...
Page 16: Viscosity Chart
V I SCOSI T Y CH ART...
Page 17: Torque Specifications Chart
T ORQU E SPECI FI CAT I ON S CH ART (HEX HEAD CAP SCREWS) Grade 5 Grade 8 Nominal Dia. Threads Per Ft. Lbs. Ft. Lbs. Inch 36 - 42 42 - 48 41 - 47 48 - 54 7/16 54 - 62 63 - 71...

Tulsa 3541RL Service Manual

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