Tulsa 354IRL User manual

3541RL3541RL
SERVICE MANUALSERVICE MANUAL
MODEL CODE .....................................................................................................................................................2MODEL CODE .....................................................................................................................................................2
!WARNING!...........................................................................................................................................................3!WARNING!...........................................................................................................................................................3
INTRODUCTION AND THEORY OF OPERATION...........................................................................................4INTRODUCTION AND THEORY OF OPERATION...........................................................................................4
MAINTENANCE ...................................................................................................................................................4MAINTENANCE ...................................................................................................................................................4
GENERAL DISASSEMBLY.................................................................................................................................5GENERAL DISASSEMBLY.................................................................................................................................5
A. MOTOR DISASSEMBLY.............................................................................................................................5A. MOTOR DISASSEMBLY.............................................................................................................................5
B. BRAKE SECTION DISASSEMBLY ............................................................................................................6B. BRAKE SECTION DISASSEMBLY............................................................................................................6
C. DRUM & INPUT GEAR SECTION DISASSEMBLY..................................................................................7C. DRUM & INPUT GEAR SECTION DISASSEMBLY..................................................................................7
D. OUTPUT GEAR SECTION DISASSEMBLY.............................................................................................8D. OUTPUT GEAR SECTION DISASSEMBLY.............................................................................................8
E. PLANET SET DISASSEMBLY AND ASSEMBLY......................................................................................8E. PLANET SET DISASSEMBLY AND ASSEMBLY......................................................................................8
GENERAL ASSEMBLY .......................................................................................................................................9GENERAL ASSEMBLY .......................................................................................................................................9
F. OUTPUT GEAR SECTION ASSEMBLY ....................................................................................................9F. OUTPUT GEAR SECTION ASSEMBLY ....................................................................................................9
G. DRUM & INPUT GEAR SECTION ASSEMBLY..................................................................................... 10G. DRUM & INPUT GEAR SECTION ASSEMBLY..................................................................................... 10
H. BRAKE SECTION ASSEMBLY ............................................................................................................... 11H. BRAKE SECTION ASSEMBLY ............................................................................................................... 11
I. MOTOR SECTION ASSEMBLY................................................................................................................ 12I. MOTOR SECTION ASSEMBLY................................................................................................................ 12
TROUBLE SHOOTING..................................................................................................................................... 13TROUBLE SHOOTING..................................................................................................................................... 13
3541RL BILL OF MATERIAL............................................................................................................................ 143541RL BILL OF MATERIAL............................................................................................................................ 14
3541RL SUB-ASSEMBLY BILL OF MATERIAL.............................................................................................. 153541RL SUB-ASSEMBLY BILL OF MATERIAL.............................................................................................. 15
VISCOSITY CHART.......................................................................................................................................... 16VISCOSITY CHART.......................................................................................................................................... 16
TORQUE SPECIFICATIONS CHART ............................................................................................................. 17TORQUE SPECIFICATIONS CHART ............................................................................................................. 17
G:\SERVICE LITERATURE\3541RL SERVICE LIT\Sel-0005.doc
Rev-0
G:\SERVICE LITERATURE\3541RL SERVICE LIT\Sel-0005.doc
Rev-0
epcatalogs.com

MODEL CODE
3541RL A L O C DWE
BASIC MODEL
A OR B DRUM WIDTH
LEFT/RIGHT MOUNT
SPOOL OVER/UNDER DRUM
CLOSE COUPLED
MOTOR OPTION
2
epcatalogs.com

!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.
2. Cable anchors on Tulsa Winches are not designed to hold the rated
load of the winch. You must keep at least five (5) wraps of cable on the
drum to insure that the cable doesn’t come loose.
3. Stay clear of the suspended loads and of cable under tension. A
broken cable or dropped load can cause serious injury or death.
4. Make sure that all equipment, including the winch and cable, is
maintained properly.
5. Avoid shock loads. This type of load imposes a strain on the winch
many times the actual weight of the load and can cause failure of the
cable or of the winch.
6. Winch operators must be trained in the proper, safe operation of the
winch.
7. Do not use EP type gear lubes in the brake section of this winch. EP
lubes may prevent the clutch from locking up, causing a load to fall, and
resulting in property damage, personal injury, or death.
8. The hydraulic system should use only high quality hydraulic oils from
reputable suppliers. These oils should contain additives to prevent
foaming and oxidation in the system. All winch hydraulic systems
should be equipped with a return line filter capable of filtering 10-micron
particles from the system.
3
epcatalogs.com

INTRODUCTION AND THEORY OF OPERATION
The 3541RL series planetary winch is designed to use a roller-vane gerotor motor, driving through a multiple
disc brake, spring assisted air operated clutch and two planet sets to the cable drum.
The multiple disc 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 the one-way cam clutch, bypassing
the brake. When the load comes to a stop, the cam clutch locks up and the load is prevented from moving by
the brake.
The brake and brake valve receives its signal any time the winch is in pay out. With the brake fully open at
about 340 PSI the brake valve will open and dynamically control the lowering of the load.
MAINTENANCE
Tulsa 3541RL series planetary winches, like any other piece of machinery, need to be periodically serviced
and well maintained to insure proper operation.
Good maintenance consists of three steps.
1. A daily inspection to insure that there are no oil leaks present, that all mounting bolts and other fasteners
are tight, and that the wire rope is in good condition.
2. Periodic servicing of the winch includes changing the oil in both the gearboxes and the brake section.
Severity of use will determine the need for oil changes but it should be checked at a minimum of every 500
hours. Factors such as extremely dirty conditions or widely varying temperature changes may dictate
even more frequent servicing.
3. Complete teardowns and component inspections. Again, severity and frequency of use will determine
how often this should be done. If the equipment that this winch is mounted on is subject to standards for
this type of inspection, then those standards must be followed. If oil changes reveal significant metallic
particles then a teardown and inspection must be made to determine the source of wear.
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. If your work calls for operation in temperatures outside this range, contact
Tulsa Winch for recommendations.
Gearbox oil in gear section is drained by removing the fill and drain plugs (items 79) located on the gearbox
cover (item 61). Gearbox oil in the drum section is drained by removing the plug (item 45) located on the
barrel of the drum (item 1). Examine the used oil for signs of significant metal deposits and then dispose of it
in a proper manner. Reinstall the plugs and fill the gearboxes with the proper amount of new SAE 90 EP gear
lube through the fill hole. Make sure the breather (item 78) is operational and replace if necessary.
Drain the brake section by removing the drain plug (item 32) and breather (item 31) in the brake cover (item
28). Inspect the oil for signs of metallic particles and/or burning and re-install the drain plug. Fill brake section
with automatic transmission fluid, or hydraulic oil.
OIL CAPACITIES
QTY TYPE
GEAR LUBE (DRUM SECTION) 3/4 qt. EP 90
BRAKE OIL 1/2-1 pt. ATF
GEAR LUBE (GEAR SECTION) 1-1/2 qts. EP 90
4
epcatalogs.com

GENERAL DISASSEMBLY
A. MOTOR SECTION DISASSEMBLY
1. Drain the oil from the brake assembly by
removing the plug (item 32) from brake cover
(item 28).
2. Remove all tubing and hoses attached to
motor. (Note the location of tubing, hoses and
fittings for re-assembly).
3. Remove the capscrews (item 71) holding
motor in place.
4. Grasp the motor and remove from winch.
5. Inspect o-ring (item 35), replace if necessary.
6. Motors are not serviceable in the field. Return
them to an authorized dealer for service.
5
epcatalogs.com