Tulsa Rufnek Intelliguard 3541RL, Service Manual

G. DRU M  &  I N PU T  GEAR SET  ASSEM BLY  

1.  Thoroughly clean all parts.  Replace those 

which show wear.  Lubricate all oil seals and 
o-rings before assembly. 

2.  After inspecting drum, shaft, bearing and seal 

for damage or wear, Install drum (item 1) over 
output sun gear, making sure that the splines 
on shaft (item 2) properly engage output gear 
set (item 60). 

3.  If applicable install cable packer. 
4.  Install side plate (item 16) by attaching 

sideplate to frames with capscrews (item 46). 

Note: Do not tighten capscrews (item 46) until 
brake housing (item 14) is attached to side 
plate (item 16).

5.  Lubricate and Insert thrust washer (item 9) into 

drum and center over output sun gear (item 
15) on top of shaft (item 2). 

6.  Insert input gear set (item 8) into drum, making 

sure that it engages the output sun gear (item 
15). 

7.  Lubricate and Insert thrust washer (item 9) into 

drum and locate in recess on input gear set 
(item 8). 

8.  Install the bearing carrier (item 10) with seal 

side facing up into drum. 

9.  Insert the input sun gear (item 44) into input 

gear set (item 8). 

10. Place the brake assembly into the winch and 

install 8 capscrews (item 49).  Tighten 
capscrews evenly to 100-110 ft. lb torque.  
Make sure that the level and vent plugs in the 
cover are properly oriented. 

11. Tighten capscrews (item 46) holding frames 

(items 22 & 23) to sideplate (item 16). 

12.  Attach all tubing and hoses to motor (item 33) 

and brake housing (item 14). 

13. Position winch horizontally and fill drum 

section with proper amount and type of 
lubricant. 

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