3541RL

SERVICE MANUAL

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
 MODEL CODE
3541RL 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

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 !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.

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 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

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 GENERAL DISASSEMBLY
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).
5. Inspect o-ring (item 35), replace if necessary.
2. Remove all tubing and hoses attached to
6. Motors are not serviceable in the field. Return
motor. (Note the location of tubing, hoses and
them to an authorized dealer for service.
fittings for re-assembly).

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 B. BRAKE SECTION DISASSEMBLY

1. 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. Carefully remove piston and polish if necessary. Friction discs
the cover (item 28) from the brake housing should measure no less than .055-in. thick and
(item 14). Inspect the o-ring (item 36) for stator plates should measure no less than
damage and replace if necessary. .068-in thick.
2. Remove the springs (item 30) from the piston 7. To dis-assemble the brake driver/clutch
(item 29) and check the free height. Each assembly, remove the retaining ring (item 37)
spring should measure at least 1.250 inches from either end of the driver. Then remove the
with no force on them. race (item 38) and bushing (item 39). Slide
3. Remove the brake piston (item 29) by the brake driver (item 41) off the drive
installing two pieces of 3/8”-16NC all thread coupling. (Note: Notice the direction of lock-
into the two holes in the top of the piston and up on the clutch for re-assembly. Inspect the
run in evenly until the piston is clear of the driver coupling and brake driver for wear.
housing. An alternate way of removing the Replace if necessary.
piston is to use a portable hydraulic power unit 8. Remove the retaining ring (item 24), then
or air to gently pressurize the brake cavity to remove the middle piston (item 21). Inspect
remove the piston from the brake housing the seal (item 43) and o-rings (items 20 & 81)
(item 14). for damage and replace if necessary.
4. If one or both the square seals (item 51) 9. Remove the clutch spring (item 47) and thrust
remain in the bore of the brake housing, washer (item 48) from brake housing.
remove them. Inspect the seals for damage 10. Grasp the sliding clutch (item 27) and remove
and replace if necessary. from the brake housing.
5. Grasp the brake driver/clutch assembly 11. Remove inner piston (item 17) from brake
(assembled items 34,37,38,39,40,41 & 42) housing. Inspect the o-rings (items 18 & 19)
and remove it from the brake housing. for damage and replace if necessary.
6. Remove the stator plates (item 25) and friction
discs (item 26) from the brake housing and

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 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.
for re-assembly). 8. Next remove the input gear set (item 8) with
2. Drain oil from drum section by removing plug thrust washers (item 9) from drum. Inspect
(item 45) located on the barrel of the drum. gear set for wear and repair as needed. (See
3. Then remove the motor and brake assembly gear set disassembly section for disassembly
by removing 8 capscrews (item 49). and assembly procedures).
4. Grasp the motor and remove the motor & 9. To remove drum the side plate (item 16) must
brake assembly from winch. be removed by removing capscrews (item 46)
5. Examine the journal on the brake housing attaching frames to sideplate. Remove side
where the seal (item 13) rides. If severely plate.
worn, replace the brake housing (item 14). 10. Remove drum by hoisting the drum straight up
Refer to brake section disassembly section for off of output sun gear (item 15).
brake housing replacement. 11. Use caution removing drum with cable packer
6. Grasp the input sun gear (item 44) and option (item 64). Cable packer is spring
remove from gear set (item 8). loaded.
7. Using two crows foot pry bars, hook the 12. Inspect seal (item 6), bearing (item 5) and
bearing carrier (item 10) in the I.D. of the shaft (item 2) located in drum for damage or
bearing (item 12) and pull out of drum. Inspect wear. Remove and replace if necessary.

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 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. Remove output sun gear (item 15), output
gear end you must start with the outer cover. gear set (item 60), and the inner race (item 7)
Remove the capscrews (item 63) and cover and inspect for Wear. Replace if necessary.
(item 61).

E. PLANET SET DISASSEMBLY AND ASSEMBLY.

1. Remove the retaining rings from the planet 5. Before assembly, be sure to insert the round
pins. thrust plate into the input carrier.
2. Remove the pins from the carrier by carefully 6. To re-assemble, be careful to line up the
tapping them out. planet pins with the thrust washers and
3. Remove the planet gears, thrust washers and bearings. Press the knurled part of the pin into
bearings from the carriers. the carrier. If the pins are not lined up
4. Inspect the pins, bearings, and gear bores for properly, the thrust washer can be shattered
evidence of wear and replace if necessary. during the pressing operation.
7. Replace retaining rings.

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 GENERAL ASSEMBLY
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. Insert output gear set (item 15) into gear 5. Install cover (item 61) by installing capscrews
housing. (item 63).
3. Install output sun gear (item 15) into output 6. Fill gear section to fill/level hole in cover with
gear set. proper type of lubricant.

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 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. (item 8).
2. After inspecting drum, shaft, bearing and seal 8. Install the bearing carrier (item 10) with seal
for damage or wear, Install drum (item 1) over side facing up into drum.
output sun gear, making sure that the splines 9. Insert the input sun gear (item 44) into input
on shaft (item 2) properly engage output gear gear set (item 8).
set (item 60). 10. Place the brake assembly into the winch and
3. If applicable install cable packer. install 8 capscrews (item 49). Tighten
4. Install side plate (item 16) by attaching capscrews evenly to 100-110 ft. lb torque.
sideplate to frames with capscrews (item 46). Make sure that the level and vent plugs in the
Note: Do not tighten capscrews (item 46) until cover are properly oriented.
brake housing (item 14) is attached to side 11. Tighten capscrews (item 46) holding frames
plate (item 16). (items 22 & 23) to sideplate (item 16).
5. Lubricate and Insert thrust washer (item 9) into 12. Attach all tubing and hoses to motor (item 33)
drum and center over output sun gear (item and brake housing (item 14).
15) on top of shaft (item 2). 13. Position winch horizontally and fill drum
6. Insert input gear set (item 8) into drum, making section with proper amount and type of
sure that it engages the output sun gear (item lubricant.
15).

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 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. Lubricate and install piston into the brake
piston (item 17) with long side down. housing and gently tap down until seated.
3. Install thrust washer (item 48), then clutch 9. Install the springs (item 30) into the spring
spring (item 47). pockets. If working in a horizontal position,
4. Insert the middle piston (item 21). While coat the bottom of each spring with chassis
holding down on piston (item 21) install lube to keep it in position.
retaining ring (item 24) 10. Install the brake cover (item 28) onto the brake
5. Insert the brake driver/clutch assembly, housing and tighten capscrews (item 49)
making sure that it engages the sliding clutch evenly, alternating between opposite
(item 27). capscrews. Make sure ports are oriented in
6. Install the stator plates (item25) and friction proper position.
discs (item 26) starting with a stator plate and 11. Check the brake release with a portable
alternating between friction discs and stator hydraulic pump. Full release should be
plates. There is one more stator plate than obtained at 320-340 psi. Also, check the
friction discs so you should end with a stator brake for proper operation by applying 280 psi
plate. Note: Soak friction discs in hydraulic oil to the brake port and adapting a torque
before installation. wrench to the input shaft. The torque in the
7. Inspect each new seal (item 51) to make sure payout direction should be 95-115 ft-lbs.
it has an o-ring in the groove of the seal. 12. Check the air operated clutch by applying 100
Install one seal into the bore of the brake psi. air to “Clutch In” and “Clutch Out” ports.
housing (item 14) with the o-ring side toward Check for leaks and proper working of clutch.
the brake pack. Place the other seal onto the

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 I. MOTOR SECTION ASSEMBLY

1. 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.
lockwashers (item 50).

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 TROUBLE SHOOTING

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. Winch clutch is slipping. Inspect the clutch and driver for wear and replace worn parts.
2. PROBLEM:
Winch will not raise the load it should.
SOLUTION:
a. Relief valve setting may be too low to allow proper lifting. Increase relief valve pressure
setting. (Note: do not exceed recommended system pressures).
b. Load being lifted may be more than the winch’s rating. Reduce the load or re-rig to
increase mechanical advantage.
3. PROBLEM:
Oil leaks from the vent on the motor side of the winch.
SOLUTION:
a. The motor shaft seal may have failed. Replace this seal and reduce backpressure if that
caused the shaft seal to fail.
b. Brake piston seals may have failed. Service the brake section and replace worn parts.

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 3541RL BILL OF MATERIAL
ITEM NO. PART NO. QTY. DESCRIPTION
1 42814 1 DRUM
2 42812 1 SHAFT
3 42827 6 PIN
4 30567 1 RETAINING RING
5 30385 1 BEARING, BALL
6 42828 1 SEAL, OIL
7 42839 2 RACE
8 4217 1 INPUT GEAR SET
9 41722 2 RACE
10 42203 1 CARRIER BEARING
11 939452 1 O-RING
12 29967 1 BALL BEARING
13 42202 1 OIL SEAL
14 42661 1 BRAKE HOUSING
15 42803 1 OUTPUT SUN GEAR
16 42663 1 SIDE PLATE
17 42924 1 AIR PISTON
18 42201 1 O-RING
19 31455 1 O-RING
20 34003 1 O-RING
21 42943 1 AIR PISTON
22 42842 1 FRAME, L.H.
23 42843 1 FRAME, R.H.
24 30600 1 RETAINING RING
25 42148 8 STATOR PLATE
26 32765 7 FRICTION DISC
27 42220 1 SLIDING CLUTCH
28 42593 1 BRAKE COVER
29 42229 1 BRAKE PISTON
30 42230 12 BRAKE SPRING
31 13050 1 BREATHER
32 21684 1 PLUG
33 43117 1 MOTOR, HYDRAULIC
34 42206 1 INPUT DRIVER
35 32566 1 O-RING
36 33094 1 O-RING
37 26980 2 RETAINING RING
38 41723 2 RACE
39 41743 2 BUSHING
40 41759 1 CLUTCH
41 41740 1 BRAKE DRIVER
42 29043 1 RETAINING RING
43 42217 1 OIL SEAL
44 42238 1 INPUT SUN GEAR
45 41719 1 PLUG, O-RING
46 42239 10 CAPSCREW
47 42241 1 SPRING, CLUTCH
48 33260 1 THRUST WASHER
49 28060 12 CAPSCREW
50 41000 4 LOCKWASHER
51 41721 2 OIL SEAL
52 32868 1 ADAPTER, 90 DEG.
53 41838 1 ADAPTER, STRAIGHT
54 42594 1 MOUNTING BRACKET
55 42595 1 TUBING
56 41603 1 COUNTERBALANCE VALVE
57 42596 1 TUBING
58 42597 1 ADAPTER, 90 DEG.
59 42534 1 CABLE THIMBLE
60 4215 1 OUTPUT GEAR SET
61 42820 1 COVER
62 23521 1 PLUG
63 20522 12 CAPSCREW
64 4218 1 CABLE PACKER

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65 42599 1 ADAPTER, STRAIGHT
66 42600 1 ADAPTER, SWIVEL 90 DEG.
67 40146 2 CAPSCREW
68 21723 2 NUT
69 21106 2 WASHER
70 42283 1 CAPLUG
71 42517 4 CAPSCREW
72 42618 1 ADAPTER, TEE
73 42494 1 HOSE ASSEMBLY
74 42620 1 ADAPTER, REDUCER
75 42033 1 TEE, SWIVEL NUT
76 41668 1 CAPLUG
77 42841 1 O-RING
78 4101 1 BUSHING & BREATHER
79 32220 2 PLUG
80 42802 1 GEAR HOUSING
81 41641 1 O-RING

3541RL SUB-ASSEMBLY BILL OF MATERIAL

SA-4217, INPUT GEAR SET (ITEM 8)

ITEM DESCRIPTION QTY. PART NO.
8-1 INPUT CARRIER 1 42838
8-2 INPUT PLANET GEAR 3 42245
8-3 PLANET PIN 3 41760
8-4 RETAINING RING 3 41715
8-5 PLATE 1 41769
8-6 BEARING 3 30484
8-7 RACE 6 28771

SA-4215, OUTPUT GEAR SET (ITEM 60)

ITEM DESCRIPTION QTY. PART NO.

60-1 OUTPUT CARRIER 1 42805
60-2 PLANET GEAR 3 42806
60-3 PLANET PIN 3 41747
60-4 RETAINING RING 3 41716
60-5 BEARING 6 41717
60-6 SPACER 3 41739
60-7 RACE 6 939249

SA-4218, CABLE PACKER (ITEM 64)

ITEM DESCRIPTION QTY. PART NO.

64-1 SPRING, L.H. 1 42344
64-2 CABLE PACKER 1 42840
64-3 SPRING, R.H. 1 42343

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VISCOSITY CHART

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 TORQUE SPECIFICATIONS CHART
(HEX HEAD CAP SCREWS)

Grade 5 Grade 8

Nominal Dia. Threads Per Ft. Lbs. Ft. Lbs.

Inch
3/8 16 36 - 42 42 - 48
24 41 - 47 48 - 54
7/16 14 54 - 62 63 - 71
20 65 - 73 76 - 84
1/2 13 80 - 90 100 - 110
20 100 - 110 120 - 130
9/16 12 105 - 115 125 - 135
18 125 - 135 150 - 160
5/8 11 170 - 180 200 - 210
18 195 - 205 230 - 240
3/4 10 285 - 295 330 - 340
16 340 - 350 400 - 410
7/8 9 495 - 505 580 - 595
14 580 - 595 685 - 700
1 8 685 - 700 805 - 820
14 825 - 840 965 - 980
1-1/8 7 1045 - 1060 1500 - 1525
12 1240 - 1260 1680 – 1705

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